Waterjet Cutting

Waterjet cutting is a versatile and precise cutting technology that uses a high-pressure stream of water or a mixture of water and abrasive materials to cut through a wide range of materials. It is often used in industries like manufacturing, aerospace, and metalworking, offering the advantage of cutting materials without generating heat, which helps maintain the integrity of the material being cut.

  • Pump: Creates the high-pressure water flow, often reaching pressures of 60,000 to 90,000 psi. It is the heart of the system.
  • Cutting Head: Directs the high-pressure water (and abrasives, if used) through a tiny nozzle onto the material.
  • Abrasive Hopper: Stores the abrasive material (such as garnet) and feeds it into the waterjet stream in abrasive cutting systems.
  • CNC Control System: Allows for precise control of the cutting head’s movement, enabling intricate patterns and designs to be cut.

Types of Waterjet Cutting

  • Pure Waterjet Cutting: This method uses only water, typically at pressures between 30,000 and 90,000 psi (pounds per square inch), to cut soft materials such as rubber, foam, textiles, paper, and some plastics. It is ideal for non-metallic materials that are easily cut with a focused water stream.
  • Abrasive Waterjet Cutting: In this method, an abrasive material (usually garnet) is added to the water stream to increase the cutting power, allowing the machine to cut harder materials such as metals, stone, ceramics, composites, and glass. The abrasive particles help to erode the material along the cut line.

Advantages of Waterjet Cutting

  • No Heat-Affected Zone (HAZ): Since waterjet cutting is a cold-cutting process, it eliminates the risk of heat-related warping, hardening, or material weakening. This makes it ideal for cutting materials that are sensitive to heat, such as metals, composites, and plastics.
  • Versatility: Waterjet cutting can handle a wide variety of materials, from soft materials like rubber, foam, and paper to hard materials like steel, aluminum, granite, ceramics, glass, and even composites.
  • Precision: Waterjet cutting offers high levels of precision, with tolerances typically around ±0.003 inches (±0.08 mm). This makes it suitable for detailed cuts, intricate patterns, and tight-fitting parts.
  • Environmentally Friendly: Waterjet cutting produces minimal waste, as there is no dust, fumes, or hazardous gases generated during the process. The water and abrasives used can often be recycled.
  • No Tool Wear: Since there is no physical contact between the cutting tool and the material, there is no wear and tear on the cutting head, making it a low-maintenance cutting solution.

Waterjet Cutting Parameters

  • Water Pressure: High pressure is crucial for cutting harder materials. Most industrial waterjet machines operate between 60,000 and 90,000 psi.
  • Abrasive Flow Rate: In abrasive waterjet cutting, the amount of abrasive material mixed with the water stream affects the cutting speed and edge quality.
  • Nozzle Size: The diameter of the nozzle controls the water stream’s width, which affects the precision of the cut. Smaller nozzles offer more precision but may cut slower.
  • Cutting Speed: The speed at which the cutting head moves across the material affects the cut quality. Faster cutting speeds may reduce precision or lead to rough edges, while slower speeds produce smoother cuts.