The Global Leader In Waterjet Cutting Solutions.

Waterjet cutting technology is one of the fastest growing major machine tool processes in the world due to its versatility and ease of operation.

There are virtually no limits to what waterjets can cut, which is why companies of all kinds and sizes are realizing greater efficiency and productivity by implementing UHP waterjets in their operations. Since Flow first invented abrasive waterjet technology in the early 1980s, the technology has evolved rapidly. Decades of research have led to the development of waterjets that do more and cost less. Heres how Flow waterjets can benefit your business: Unmatched Versatility Flow waterjets enable you to cut a variety of applications with ease. Whatever the shape, dimensions, or material, our easy-to-use software makes the job easy. Expanded Capabilities Whatever your business automotive, aerospace, stone and tile, tool and die, gaskets, fabricator, or job shop you can cut metal, stone, plastics, composites, glass, ceramics, rubber and more. Zip through materials up to 8 inches thick with no heat-affected zone and superior edge quality. Reduced Material and Production Costs Flow waterjets require minimal fixturing and tooling so you can save valuable time on your shop floor. Waterjets cut accurate, clean edges that allow for tight nesting and reduced scrap saving you money through greater material utilization.

Complements Existing Technology Many job shops add waterjets to their operations alongside other cutting technologies such as EDM, laser, milling and plasma. While each shop has its own requirements for cutting projects, most are finding waterjets to be a tremendous asset to their operations enhancing both productivity and profitability. The Technology The heart of any waterjet system is the ultrahigh-pressure pump. Learn more about Flow's UHP Pumps in our Products section. For a more in-depth look at the technology behind the waterjet, read our white paper on How Waterjets Work.

A History of Leadership
A small group of former Boeing research scientists started Flow Research (now Flow International Corporation) nearly 40 years ago, and weve been at the forefront of ultrahigh-pressure (UHP) technology ever since. Heres the story of how Flow grew from a humble start-up to a respected innovator with 60 percent worldwide market share.

1950's
Dr. Norman Franz, a forestry engineer seeking new ways to slice trees into lumber, becomes the first person to study UHP as a cutting tool. By dropping heavy weights onto columns of water to force the water through a tiny orifice, Dr. Franz obtains short bursts of very high pressures that are powerful enough to cut wood and other materials.

1974
Flow founded.

1975
Flow commercializes intensifier pumps for 24/7 operation. The first major application of this technology is commercialized for cutting disposable diapers.

1979
Dr. Mohamed Hashish invents the process of adding abrasives to a standard waterjet. After testing a variety of options, he settled on garnet, a substance commonly used on sandpaper. The UHP abrasive waterjet can now cut virtually any hard material.

1980
Abrasive waterjets are used for the first time to cut steel, glass and concrete.

1983
Flow sells the world's first commercial abrasive waterjet cutting system for automotive glass. Early adopters of waterjet technology -- primarily in the aviation and space industries -- find its a perfect tool for cutting high-strength materials such as Inconel, stainless steel and titanium, as well as light-weight composites such as carbon fiber.

1984
Flow introduces 55,000 psi (3,800 bar) intensifier pumps.

1986
Flow invents the first UHP direct drive pump, the 36,000 psi (2,400 bar) X-Pump. world's first mobile UHP waterjet pumping system is introduced for mobile and field applications such as industrial cleaning, roadway maintenance and infrastructure refurbishment projects. The

1987
Mobile waterjets enjoy a brush with fame when a system developed by Flow is used to extract "Baby Jessica" from the abandoned well into which she fell. The waterjet system digs a parallel shaft, then breaks through the wall of the well. Flow develops the first 5-Axis abrasive waterjet system capable of three-dimensional cutting. Flow creates UltraPierce Vacuum Assist for reliable piercing.

1990
Flow introduces FlowPro Database Software, the first Intelligent Control System.

1992
Flow introduces the world's first 40,000 psi (2,700 bar) triplex pump.

1995
Flow becomes the world's first single source waterjet system supplier. Flow introduces the world's first 50,000 psi (3,400 bar) triplex pump.

1996
Flow launches FlowMaster Windows based intelligent waterjet control software.

Flow introduces the Bengal, the first fully integrated waterjet system.

1997
Flow introduces 87,000 psi (6,700 bar).

1998
Flow introduces 60,000 psi (4,100 bar) intensifier. Flow introduces the IFB which quickly becomes the world's best selling waterjet system. Flow introduces ESL ceramic components to double pump seal life and increase reliability.

2001
Flow launches Dynamic Waterjet to eliminate taper, increase cut accuracy and speed. Flow develops HyPlex pumps, the world's first 55,000 psi (3,800 bar) triplex pump family.

2002
Flow introduces state-of-the-art WMC, a complete abrasive waterjet system.

2005
Flow introduces Paser ECL.

2008
Flow develops FlowConnex to remotely monitor machine operation and productivity.

2009
Dynamic Waterjet XD integrates new 3D functionality with our current Dynamic Waterjet Taper Control System.

2010

Introduces FlowXpert 3D programming.

Today
Ironically, the wood-cutting application that Dr. Franz first researched is now just a minor use of UHP waterjet technology. Waterjets are used to cut everything from aluminum for boats, to composites for sporting goods, to fabric and plastics used for automotive interiors, and even granite for kitchen countertops. Industrial cleaning applications include ship hulls, oil storage tanks, roadways, jet engines and even automotive car carriers. The basic technology is both simple and extremely complex.

At its most basic, water flows from a pump, through plumbing and out a cutting head. It is simple to explain, operate and maintain. The process, however, incorporates extremely complex materials technology and design. To generate and control water at pressures of 87,000 psi requires science and technology not taught in universities. At these pressures a slight leak can cause permanent erosion damage to components if not properly designed. Thankfully, the waterjet manufacturers take care of the complex materials technology and cutting-edge engineering. The user need only be knowledgeable in the basic waterjet operation. Essentially, there are two types of waterjets:
See How a Waterjet Works!

Pure Waterjet

Abrasive Waterjet

Flow machines are designed to operate as both pure and abrasive waterjets. A pure waterjet is used to to cut soft materials, and within just 2 minutes the very same waterjet can be transformed into an abrasive waterjet to cut hard materials. With any type, the water must first be pressurized.

Waterjet: Cutting Comparison With Other Methods

Waterjets can cut any solid material including stone, tile, glass, metal, foam, rubber, plastic, and food. When compared with plasma, laser, and edm - waterjet cutting has distinct advantages.

Waterjet continues to grow faster than other processes:

WATERJET vs. Plasma vs. Laser vs. EDM

In addition to no heat-affected zone, the benefits and applications for waterjet technology are limitless and everexpanding. In comparison to other cutting technologies:

Waterjet

Plasma

Laser

EDM

Process

Erosion process: high speed liquid sandpaper

Burning / Melting melting process process using using high concentrated temperature laser light beam ionized gas arc

Erosion process using electrical discharge

Materials

Any material. Primarily steel, Primarily steel, Conductive stainless steel stainless and materials only. and aluminum. aluminum. Can also cut a variety of other materials. Up to 24 Up to 2-3 inches, Generally 1 inch inches, depending on or less, virtually any material. depending material. on materials. Z constraint is only limit to thickness. Up to .001" Up to .010" $60k to over $300k Up to .001" $200K to over $1M Generally 12 inch or less.

Thickness

Part Accuracy

Up to .0001" $100k to over $400k Different wire types for different jobs

Capital $60k to over $300k Investment Machine Setup Same setup for all materials

Different Different gases setup for and parameters different jobs for different jobs

As the grid above illustrates - and the image to the right shows, waterjet cutting technology has clear advantages over other cutting methods. Green Benefits Waterjet cutting is a cold-cutting process that eliminates slag deformation and dross waste unfortunate effects found in plasma and laser cutting processes. Additionally, both the garnet used in abrasive cutting as well as the water are recycable. Pure waterjet is the original water cutting method. The first commercial applications were in the early to mid 1970s, and involved the cutting of corrugated cardboard.

The largest uses for pure waterjet cutting are disposable diapers, tissue paper, and automotive interiors. In the cases of tissue paper and disposable diapers the waterjet process creates less moisture on the material than touching or breathing on it.

Pure Waterjet Attributes Very thin stream (0.004 to 0.010 inch in diameter is the common range)

Extremely detailed geometry Very little material loss due to cutting Non-heat cutting Cut very thick Cut very thin Usually cuts very quickly Able to cut soft, light materials (e.g., fiberglass insulation up to 24" thick) Extremely low cutting forces Simple fixturing 24 hour per day operation Abrasive waterjet cutting differs from pure waterjet cutting in just a few ways. In pure waterjet cutting, the supersonic stream erodes the material.

In the abrasive waterjet, the waterjet stream accelerates abrasive particles and those particles, not the water, erode the material.

The abrasive waterjet is hundreds, if not thousands of times more powerful than a pure waterjet. Both the waterjet and the abrasive waterjet have their place. Where the pure waterjet cuts soft materials, the abrasive waterjet cuts hard materials, such as metals, stone, composites and ceramics. Abrasive waterjets using standard parameters can cut materials with hardness up to and slightly beyond aluminum oxide ceramic (often called alumina, AD 99.9). Abrasive Waterjet Attributes Extremely versatile process No Heat Affected Zones No mechanical stresses Easy to program Thin stream (0.020to 0.050 inch in diameter) Extremely detailed geometry Thin material cutting 10 inch thick cutting Stack cutting Little material loss due to cutting Simple to fixture Low cutting forces (under 1 lb. while cutting) One jet setup for nearly all abrasive jet jobs Easily switched from single to multi-head use Quickly switch from pure waterjet to abrasive waterjet Reduced secondary operations Little or no burr

See Abrasive Waterjet!

Abrasive waterjet cutting differs from pure waterjet cutting in just a few ways. In pure waterjet cutting, the supersonic stream erodes the material.

In the abrasive waterjet, the waterjet stream accelerates abrasive particles and those particles, not the water, erode the material.

The abrasive waterjet is hundreds, if not thousands of times more powerful than a pure waterjet. Both the waterjet and the abrasive waterjet have their place. Where the pure waterjet cuts soft materials, the abrasive waterjet cuts hard materials, such as metals, stone, composites and ceramics. Abrasive waterjets using standard parameters can cut materials with hardness up to and slightly beyond aluminum oxide ceramic

See Abrasive Waterjet!

(often called alumina, AD 99.9). Abrasive Waterjet Attributes Extremely versatile process No Heat Affected Zones No mechanical stresses Easy to program Thin stream (0.020to 0.050 inch in diameter) Extremely detailed geometry Thin material cutting 10 inch thick cutting Stack cutting Little material loss due to cutting Simple to fixture Low cutting forces (under 1 lb. while cutting) One jet setup for nearly all abrasive jet jobs Easily switched from single to multi-head use Quickly switch from pure waterjet to abrasive waterjet Reduced secondary operations Little or no burr DYNAMICALLY SUPERIOR PARTS

Ultimate in Accuracy, Speed, and Flexibility Dynamic Waterjet XD integrates 3D functionality with Dynamic Waterjet -- giving you the ultimate in accuracy, speed, and flexibility. Dynamic XD is a revolutionary waterjet advancement, and is industry altering in its unique features and capabilities. It offers advanced beveling and up to 60 degrees of motion. This functionality provides added versatility and allows for easy cutting of complex parts in 3D. However, beyond these core capabilities is the ability to cut 3D parts using Flow's patented Dynamic Waterjet Technology. Our original Dynamic Waterjet technology was invented and patented by Flow in 2001. You can cut up to 2 4 times faster, to high precision and tight corner geometry is easily completed with this exclusive technology. Dynamic Waterjet automatically compensates for stream lag and taper, natural occurrences of the waterjet process. Its articulated wrist allows the cutting head to tilt in any direction, compensating for waterjet stream imperfections using complex mathematical models. These calculations are all completed behind the scenes, by our smart FlowXpert Software Suite, without the necessity of operator participation using our SmartStream Technology. All you have to do is select the material type from the comprehensive database of tested materials, input thickness, and your part will come out perfect the first time. The core technology of Dynamic Waterjet combined with advanced 3D capabilities provides you with the ultimate cutting option. Other manufactures claim that they have BOTH 3D cutting and taper compensation. Flow can prove it. Flip it over.
Watch Dynamic XD Cut!

Features Include: Rapid lift and drop is accomplished by precision electric drive Position feedback provides closed-loop control of the Z Provides up to 60 of motion Underwater or above water operation 6 inch (152 mm) vertical travel Easy access cover protects critical precision components Laser-alignment using Flows exclusive Dynalign System to ensure ultimate precision! The Most Advanced and Robust High Pressure System Available

94,000 psi rated pumps vs. 60,000 psi rated pumps: Cuts 30-50% faster Uses 30-50% less abrasive

Delivers 20-30% lower part cost Extremely fast and simple maintenance

Since the inception of waterjet cutting in the early 1970's, cutting pressures have consistently and steadily increased. The reason is simple, Pressure = Productivity. Increase the waterjet pressure and the stream moves faster, reduces in diameter, and uses less abrasive (the highest cost consumable). CUT FASTER Flow's HyperPressure pump, called the HyperJet 94i, is rated at 94,000 psi and delivers continuous operating pressure at an incredible 87,000 psi, a large increase in pressure from traditional 55,000 to 60,000 psi rated ultrahigh-pressure systems. Much as the wattage of a CO2 laser increases cut speed, increased water pressure increases cut speed. As the pressure goes up the stream velocity increases, delivering greater cutting power density. With the 94i HyperJet pump, stream velocities approach Mach 4, four times the speed of sound. From stone to aluminum, steel to exotic composites, increases of 30-50% in cutting speeds are a result of accelerating the abrasive waterjet stream to the fastest level available. Regardless of material or thicknesses, cutting speeds increase with higher pressure. LOWER COSTS Higher speeds and increased production doesn't come at a higher cost 94i HyperJet pumps cost less to operate. The savings comes from the abrasive. Abrasive constitutes 2/3 of the machine operating cost, and as pressure goes up, the stream moves faster and becomes smaller in diameter. Less abrasive is then entrained into the stream, but each particle carries more momentum and cutting power. HyperPressure pumps can operate at 45% higher pressure or more compared to standard pumps. With abrasive costs representing a majority of the operating cost of any waterjet pump, using 30-50% less abrasive with a HyperPressure pump will save money. This results

in a lower operating cost than traditional pumps at lower pressure while yielding much faster cutting. Lower operating costs combined with increased speeds mean the cost per part or contract job will be greatly reduced. The option of running a more efficient shop, producing more parts in less time at a lower cost makes the exclusive Flow HyperPressure pump a clear choice. INCREASE PRODUCTION Faster cutting speeds mean more parts can be cut; throughput for any shop will increase. From in-house production to custom fabrication and contract manufacturing shops, more jobs can be completed in less time with a 94i HyperPressure pump. As business grows and floor space becomes scarce, additional machinery is an undesirable answer. Increased production capability with Flow's exclusive 94i HyperPressure pump will accommodate growth in every business without increasing floor space, utility requirements or employees. he pump is the heart of the waterjet system. The pump pressurizes the water and delivers it continuously so that a cutting head can then turn that pressurized water into a supersonic waterjet stream.

Two types of pump can be used for waterjet applications an intensifier based pump and a direct drive based pump.

Direct Drive Pump

The direct drive pump operates in the same manner as a lowpressure "pressure washer" that you may have used to pressure wash a house or deck prior to repainting. It is a triplex pump that gets the movement of the three plungers directly from the electric motor. These pumps are gaining acceptance in the waterjet industry due to their simplicity. At the time of this writing, direct drive pumps can deliver a maximum continuous operating pressure 10 to 25% lower than intensifier pumps units (20k to 60k for direct drive, 40k to 94k for intensifiers). Though direct drive pumps are used in some industrial applications, the vast majority of all ultra-high pressure pumps in the waterjet world today are intensifier based.

Intensifier Pump
Two fluid circuits exist in a typical intensifier pump, the water circuit and the hydraulic circuit. The water circuit consists of the inlet water filters, booster pump, intensifier, and shock attenuator. Ordinary tap water is filtered by the inlet water filtration system usually comprising of a 1 and a 0.45 micron cartridge filter. The filtered water then travels to the booster pump, where the inlet water pressure is maintained at approximately 90 psi ensuring the intensifier is never "starved for water." The filtered water is then sent to the intensifier pump and pressurized to up to 94,000 psi. Before the water leaves the pump unit to travel through the plumbing to the cutting head, it first passes through the shock attenuator.

This large vessel dampens the pressure fluctuations to ensure the water exiting the cutting head is steady and consistent. Without the attenuator, the water stream would visibly and audibly pulse, leaving marks on the material being cut. The hydraulic circuit consists of an electric motor (25 to 200 HP), hydraulic pump, oil reservoir, manifold, and piston biscuit/plunger. The electric motor powers the hydraulic pump. The hydraulic pump pulls oil from the reservoir and pressurizes it to 3,000 psi. This pressurized oil is sent to the manifold where manifolds valves create the stroking action of the intensifier by sending hydraulic oil to one side of the biscuit/plunger assembly, or the other. The intensifier is a reciprocating pump, in that the biscuit/plunger assembly reciprocates back and forth, delivering high-pressure water out one side of the intensifier while lowpressure water fills the other side. The hydraulic oil is then cooled during the return back to the reservoir. The advanced technology in the pump is found in the intensifier.

As mentioned briefly in the description of the water circuit, the intensifier pressurizes the filtered tap water to up to 60,000 psi. Intensifier pumps utilize the intensification principle. Hydraulic oil is pressurized to a pressure of, say, 3,000 psi. The oil pushes against a piston biscuit. A plunger with a face area of 20 times less than the biscuit pushes against the

water. Therefore, the 3,000-psi oil pressure is intensified twenty times, yielding 60,000psi water pressure. The intensification principle varies the area component of the pressure equation to intensify, or increase, the pressure. Pressure = Force /Area If Force = 20, Area = 20, then Pressure = 1. If we hold the Force constant and greatly reduce the Area, the Pressure will go UP. For example, reduce the Area from 20 down to 1, the Pressure now goes up from 1 to 20. In the sketch below, the small arrows denote the 3,000 psi of oil pressure pushing against a biscuit face that has 20 times more area than the face of the plunger. The intensification ratio, therefore, is 20:1.

In the illustration below, the biscuit and plungers are in the green section and outlined in red. The biscuit contains the small arrow suggesting movement to the left. The two water plungers extend from either side of the biscuit. High-pressure water is delivered out the left side while low-pressure water refills the right. At the end of travel, the biscuit/plunger assembly sequence is reversed.

(click image for larger version)

Sophisticated check valves ensure the low pressure and high-pressure water is only allowed to travel one direction. The high-pressure cylinders and end caps that encase the plunger and biscuit assembly are specially designed to withstand the enormous force and the constant fatigue. The advanced technology in the pump is found in the intensifier.

As mentioned briefly in the description of the water circuit, the intensifier pressurizes the filtered tap water to up to 60,000 psi. Intensifier pumps utilize the "intensification principle." Hydraulic oil is pressurized to a pressure of, say, 3,000 psi. The oil pushes against a piston biscuit. A plunger with a face area of 20 times less than the biscuit pushes against the water. Therefore, the 3,000-psi oil pressure is "intensified" twenty times, yielding up to 94,000-psi water pressure. The "intensification principle" varies the area component of the pressure equation to intensify, or increase, the pressure. Pressure = Force /Area If Force = 20, Area = 20, then Pressure = 1. If we hold the Force constant and greatly reduce the Area, the Pressure will go UP. For example, reduce the Area from 20 down to 1, the Pressure now goes up from 1 to 20. In the sketch below, the small arrows denote the 3,000 psi of oil pressure pushing against a biscuit face that has 20 times more area than the face of the plunger. The intensification ratio, therefore, is 20:1.

In the illustration below, the biscuit and plungers are in the green section and outlined in red. The biscuit contains the small arrow suggesting movement to the left. The two water plungers extend from either side of the biscuit. High-pressure water is delivered out the left side while low-pressure water refills the right. At the end of travel, the biscuit/plunger assembly sequence is reversed.

Sophisticated check valves ensure the low pressure and high-pressure water is only allowed to travel one direction. The high-pressure cylinders and end caps that encase the plunger and biscuit assembly are specially designed to withstand the enormous force and the constant fatigue.

A distinct difference exists between part accuracy and the accuracy in which a machine can move.

Simply buying a 0.00000000000001" accurate machine, with perfect dynamic motion, perfect velocity control, and dead-on repeatability will not mean you will cut perfect parts. It will, however, mean you will spend a lot of money on the super-accurate machine. Finished part accuracy is a combination of process error (the waterjet) + machine error (the XY performance) + workpiece stability (fixturing, flatness, stable with temperature). The section below describes part errors which would occur even if the waterjet machine was perfect. The waterjet beam has characteristics that greatly affect part accuracy. Controlling these characteristics has been the focus of waterjet suppliers for many years. Simply put, a highly accurate and repeatable machine may eliminate machine motion from your part accuracy equation, but it does not eliminate other part errors (such as fixturing errors and inherent waterjet stream errors). When cutting materials under 1 inch thick, a conventional waterjet machine typically cuts parts from +/-0.003 to +/-0.015 inch (.07 to .4 mm) in accuracy. A machine equipped with Dynamic Waterjet can cut parts as accurate as +/- 0.001 inch. For materials over 1 inch thick the machines will produce parts from +/- 0.005 to 0.100 inch (.12 to 2.5 mm). A high performance XY table is designed to have an accuracy of about 0.005-inch linear positional accuracy or better. So where do the part inaccuracies come from?

Beam Deflection or "Stream Lag"

When the waterjet, or other beam type cutters like laser or plasma, are cutting through the material, the stream will deflect backwards (opposite direction of travel) when cutting power begins to drop. This problem causes: increased taper, inside corner problems, and sweeping out of arcs. Reduce this lag error by increasing cutting power or slowing down the cut speed. Increased Taper A "V" shaped taper is created when cutting at high speeds. Taper can be minimized or eliminated by slowing down the cut path or increasing cutting power. Inside Corner Problems When cutting an inside corner at high speed, the stream can dig into the part as it comes out of the corner. Sweeping Out of Arcs When cutting at high speed around an arc or circle the stream lag sweeps out a cone. Fixturing Even though the waterjet delivers under pound of vertical force when cutting a high quality part and under 5 pounds when rough cutting, proper fixturing is required to produce accurate parts. The part must not move during cutting or piercing, and it must not vibrate. To minimize these errors try to butt the workpiece up against the edge of the catcher or a solid bar stop secured to the table slats. Look for material

vibration or movement during cutting the first article. Material Instability Some materials, like plastics, can be very sensitive to temperature changes. Called thermal expansion, these materials may expand when slightly heated or shrink when cooled. During waterjet cutting the material does not get hot, but it can get warm. Also, be especially careful of air gaps in cast material, as the stream tends to open up in air gaps. The AWJ will not induce warpage in sheet material. It will, however, relieve stresses. If you are working with a sheared material <0.125 inch thick and you start your cut path off the part, enter into the part, and then cut the part, you may see the material twist and warp. Avoid this warpage whenever possible by beginning cut paths from within the material (pierce a hole and begin cutting) as opposed to beginning from outside of the material. Pump Issues Beyond the obvious pump issues such as ensuring that the pump is delivering water at the set pressure, other issues can also impact part accuracy. If the pump has 2 or more intensifiers, do the intensifiers always stroke at the same time? If so, then look on the part for vertical marks on the cut edge that match in frequency with the stroking. Check valves should be in good working order. Water Pressure at the Nozzle Cut speed can be lost if excessive pressure drops (greater than 2,500 psi) exist in the high pressure plumbing run from pump to head.

Ensure the in-line filter, usually located near the cutting head, is free of excessive buildup. If you have made any changes to the plumbing run (changed the route, replaced a large line with a smaller replacement line, etc.) then ensure that you have not created larger pressure drops. Any loss of pressure between the pump is to be minimized. Pressure is cut speed, cut speed is money. Cutter Comp Error Cutter compensation is the value entered into the control system that takes into account the width of cut of the jet; in effect, you are setting the amount by which you are enlarging the cut path so that the final part comes out to proper size. Before you perform any high precision work where finished part tolerances are better than +/- 0.005 inch, cut a test coupon and ensure you have properly set the cutter compensation. Many a good drawing has been cut wrong because the operator did not take the time to establish the best cutter compensation value. Programming Error Often the most difficult of all part accuracy errors to find is a programming error where the dimension of the part program does not perfectly match the dimension of the original CAD or hand drawn drawing. Part programs that appear graphically on the screen of an XY control typically do not display dimensions. Therefore, this error can go undetected. When all else fails, double check that the dimensions on the part program match exactly those of the original drawing. Abrasive Mesh Size Typical abrasive mesh sizes are 120, 80, and 50 (similar to sand paper you

might use for woodworking). The different mesh sizes do not have a significant impact on part accuracy. They have a greater impact on surface finish and overall cut speed. Finer abrasives (larger mesh number) produce slower cuts and smoother surfaces. Machine Motion The positional accuracy and dynamic motion characteristics of a machine have an impact on the part accuracy. There are many aspects to machine motion performance. A few are: Backlash in the mechanical unit (changes in direction, is there slop in the gears or screw when the motor changes from clockwise to counterclockwise?), repeatability, will the machine come back close to the same point over and over? Servo tuning is important. Improper tuning will cause backlash, squareness, repeatability errors, and can cause the machine to chatter (wiggle at high frequency) when moving. Position accuracy is important, as well as straightness, flatness, and parallelism of the linear rails. Small part, under 12 inches in length and width, do not demand as much from the XY table as larger parts. A large part measuring, for example, 4x4 ft, will be greatly impacted by machine performance. A small part will not see position accuracy, or rail straightness as a major impact on finished part tolerance simply because the small part masks machine errors. Large parts expose such errors more evidently. Remember that a machine motion characteristic does not directly correspond to finished part tolerance. An expensive super-precision machine (linear position accuracy of, for example, +/- 0.001" over full travel, will not automatically generate a finished part of +/- 0.001" other part accuracy factors are still there (see above).
As with any purchase, the wants and needs must be weighed with a practical eye. A variety of machines exist, yielding a number of different price levels. By closely examining your

production needs and matching the machine to it, you can minimize unnecessary expenditures.

Application Workup: Materials and thickness intended to cut with WJ This list suggests pump size. Parts over inch thick should be cut with at least 50 HP per head. Smaller heads are more expensive per inch. However, sometimes it can be very effective to run two small heads instead of one large head. Examining cycle times and cost per part for each configuration will help show whether one or two heads is most productive. Stock plate sizes Sizing a machine for an oddball large plate size can be an expensive approach. It is often cheaper to cut an oversized plate down before putting it on a waterjet, or letting the oversized plate overhang out of the catcher. Finished part accuracy required? As with the plate size, you should consider the majority of the work you do, not THE most accurate. Is a 100 to 250 RMS sand blasted surface finish acceptable "as cut"? If you do not have to perform secondary operations to obtain a very smooth surface (better than 100 RMS), then your costs per part should be quite low on a waterjet. In hard materials, like hardened steels, titanium, nickle allows, ceramics, the roughing out of a part with a waterjet still may save significant cost, even when final finishing is required.

Operator proficiency? Are your operators also your programmers? Is it difficult to get and to hold programmers and operators? If so, then an intelligent control will improve your productivity greatly over the more complex and hard to learn CAM to CNC based systems. Who will perform maintenance? If the operator is also the maintenance person, then ensure adequate training is provided. You may want to consider purchasing an additional on-site operator and maintenance training day (or two) 60 days after installation. Will the operator run just the waterjet machine, or other machines too? If the operator will be running more than just one machine at a time, then look into technology that aids automated operation. For example, from some manufacturers you can purchase a cutting performance monitor that will automatically stop the machine if any deviation from peak efficiency occurs. Or, if your batch size permits, look to stack cutting. The jet on-time is extended but part production is very high. The operator can be running another machine while the jet is cutting. Will you be nesting parts on a plate? Many nesting packages are available. Although a generic nesting package can create a nest for a waterjet machine, it is typically understood that nesting packages (and machine tool controls) that are designed for a specific process are more powerful and easier to use than the generic, multi-process version. Do I have the facilities? Be prepared to discuss with the manufacturer all facilities issues. Floor space, power, water, compressed air, drainage, material storage, material loading, clean shop area for highpressure maintenance, programming office area. Hopefully you will find that reading through these tips provides you with more insight into the process. Some of the tips are obvious, while others are only seen through experience.

1.

Cutting Thick Material

When cutting under 0.100 inch thick material little is gained by using medium (50 HP) or large (60 to 80 HP) cutting heads. Use a small parameter combination (25HP) and consider multiple head to increase production if needed. 2. Cutting Through Air Gaps

Avoid cutting through air gaps greater than 0.020". The jet tends to open up in the gap and cut the lower layer roughly. When stack cutting, keep the sheets together. 3. Smaller Abrasive Grains

Smaller abrasive grains (120 mesh or smaller) will produce a slightly slower speed but slightly smoother surface (as compared to 80 or 50 mesh). 4. Productivity Is Cost Per Inch

Productivity is cost per inch, not cost per hour. It matters very little how much it costs per hour to run an abrasive waterjet. What matters is how many parts you get off in a given length of time. Some users make the mistake of trying to reduce operating cost by minimizing the abrasive flow rate. Even though abrasive is 2/3 of the abrasive waterjet operating cost, you must produce parts quickly to consume your overhead (labor, facilities, lease payment). Cut as fast as possible, using all available horsepower and the peak abrasive flow rate. 5. Water Pressure Lowered And Raised By The Controller

If you intend to pierce composites, glass, and stone on a regular basis, ensure the system has the ability to have the water pressure lowered and raised by the controller. Also, you

should investigate vacuum assist or other techniques to improve probability of successfully piercing these brittle or laminated materials. 6. Control Systems Specifically Designed For A Process

Control systems specifically designed for a process are typically more efficient and easier to use than generic multi-process controls. 7. Material Handling Automation

Most machines do not employ material handling automation, such as shuttles. Only when material handling constitutes a significant portion of part production cost should automation be considered. 90% of all Abrasive waterjet machines are loaded and unloaded either by hand or with the aid of simple overhead cranes, jib cranes, or fork lifts. 8. Ordinary Tap Water

Ordinary tap water is used to feed the waterjet systems. 90% of all waterjet and abrasive waterjet users require only water softening prior to sending that water through the pumps inlet water filters and then to the intensifier. Reverse Osmosis (RO) and De- Ionizers tend to make the water so pure that it becomes ion starved. This aggressive water seeks to satisfy its ion starvation by taking ions from surrounding materials, such as the metals in the pump and high-pressure plumbing lines. RO and De-I can greatly extend orifice life, while simultaneously performing very expensive damage to the intensifier and plumbing. Orifices are rather inexpensive. High-pressure cylinders, check valves, and end cap damage will far outweigh orifice life improvements. 9. Cutting Underwater

Cutting underwater reduces surface frosting or hazing found on the top edge of an abrasive waterjet cut. Cutting underwater also greatly reduces jet noise and workplace mess. The only negative is that operators cannot see the jet clearly during cutting. If the operator objects to underwater cutting, consider electronic performance monitoring. These monitors will detect deviation from peak cutting performance and stop the system prior to part damage. 10. Different Abrasive Mesh Sizes If you plan on using different abrasive mesh sizes for different jobs, consider adding a small (100 pound) or large (500 to 2,000 pound) bulk transfer. Without having a bulk transfer hopper for each mesh size you regularly run, you may produce downtime and nuisance along with your production.

11. Break Out Tabs Break out tabs can prove effective for cutting of materials under 0.3 inch thick. Although break out tabs generally guarantee youll need a secondary operation of grinding off the tabs, their usage allows material handling to be performed faster simply unload a cut sheet with the cut parts still in tact. The harder the material, the smaller the break out tab should be. Consult your manufacturer for detailed suggestions.