Water Under the Bridge
More options for cost-effective, profitable waterjet cutting
There are multiple options available to job and production shops looking to add or expand waterjet cutting capability; recent waterjet offerings demonstrates that manufacturers are paying attention to industry demands to meet a variety of concerns and requirements. One major trend is for machines that are easy to maintain and provide rapid access to replace parts and deal with standard wear and tear to reduce downtime on the floor, be it for immediate repairs or scheduled maintenance. Software is always a major factor to ensure that a machine operates at maximum efficiency, operators can easily input data and commands, and increasingly, that the equipment is connected to a firm’s IT structure.
Some manufacturers are stressing a combination of affordability and high quality, while others note how energy efficient their machines are, crucial where energy prices continue to climb. And without a doubt, having multiple options to be able to complete completed and standard orders is essential. One common factor continues to be higher performance and this is behind many of the advances in technology. Here are some options for Canadian waterjet users.
Mitsubishi – The MWX3 Waterjet
Mitsubishi introduces its first entry-level waterjet machine, the MWX3, which the company states is “ideal for production environments and customers new to waterjet,” and features a “solid base construction and cantilever head design make it both reliable and affordable.” Programming options are controlled by a Mitsubishi 720 CNC system; its 15-inch waterproof screen with improved graphics and NC design capabilities simplify operations. An easy-to-use menu and help function guide the operator via programming and workpiece setup.
Its standard high pressure S-50 KMT pump provides 60,000 PSI of water traveling up to Mach 2, with 1.09 GPM of water consumption through a maximum orifice size of 0.013 inches. Its reciprocating hydraulic piston-to-ceramic water piston ratio is 20:1 – this pushes water into an accumulator that maintains a smooth even flow to the cutting nozzle.
Jet Edge – X-Stream waterjet intensifier pumps (model xP90-100)
Jed Edge’s X-Stream waterjet pumps cuts material up to 50 percent faster and reduce operating costs up to 40 percent. The pumps support 75,000 PSI of continuous operating pressure and are available in 50hp and 100hp models.
The X-Stream produces 50 percent more pressure than a standard 60,000 PSI intensifier pump, resulting in a 40-50 percent increase in productivity for many materials. Compared to 60,000 PSI pumps, Jet Edge X-Stream pumps use 30 percent less water, 30 percent less power, and up to 50 percent less abrasive. The 50hp X-Stream xP90-50 produces flow rates of 0.7 gpm and supports up to a .011 inch orifice, while the 100hp xP90-100 produces flow rates of 1.45gpm and supports up to a .017 inch orifice. Fittings and tubing are rated for 100KSI. The X-Stream is backed by nearly 10 years of extensive research and development.
Bystronic - ByJet Smart Waterjet Cutting System
Bystronic’s ByJet Smart Waterjet Cutting System, states the company, is “economically priced to acquire and maintain,” but is also a powerful machine that offers “reduced operating costs [because] the pump has a very high efficiency and operates extremely reliable so that the service intervals are longer than average. [Its] high precision cutting heads, combined with abrasive metering and constant automatic nozzle height sensing, delivers unmatched part precision and consumable efficiencies.”
Among its high-end components are an innovative cutting bridge fitted with a linear motor and a precision manufactured machine frame constructed of highly-damping composite material.
“The result of this smart combination of a proven concept and innovative technology is a durable machine with an outstanding cutting performance,” states the press release.
KMT Waterjet – Streamline PRO2 series pumps
KMT Streamline PRO2 pumps provide pressure up to 90,000psi in 60hp and 125hp models that “offer the industry’s most powerful combination of horsepower and pressure with significant advances in uptime with quick and easy maintenance,” states a company press release.
The pumps feature a precision rapid change UHP intensifier, with the following benefits: a reduction in seal change time by 50 percent versus comparable UHP pumps, a low torque hard seal end cap design, the elimination of complicated bolt tensioning and tie rods, a reduction in specialty maintenance tools, longer seal life and consumable parts, improved cylinder alignment, fewer component parts, and new titanium seats and heat treat.
“When combined with PRO Line Cutting Heads,” states the press release, “the Streamline PRO2 UHP pump easily cuts up to 100% faster than traditional 60,000 PSI cutting.”
Flow International Corporation – Mach 4c
The Mach 4c is the latest addition to Flow International’s line of waterjets. Billed by the company as “the system that is years ahead,” it offers a variety of features unique in the waterjet industry including an expandable modular design, up to 14m in length that allows customers to increase the cutting area as their business grows, and provides fast, accurate machine motion with zero backlash.
Ergonomically designed to improve operator convenience and productivity, including lighting to enhance work piece visibility, it has efficient abrasive removal and full four-sided access to material and parts.
“The Mach 4c is a significant step forward in waterjet technology.” says Tim Fabian, global product manager. “The tremendous accuracy, cut speeds, modular and ergonomic design have enabled the Mach 4c to set new benchmark as the industry’s flagship system.”
OMAX Corporation – OMAX 80X JetMachining Center
OMAX Corporation’s 80X JetMachining Center is designed for “large-scale precision machining of larger or multiple parts, and is equipped with patent-pending Intelli-TRAX, the innovative linear drive technology that ensures higher positioning accuracy,” states a company press release. Intelli-TRAX’s linear drive is fully enclosed inside coated steel covers, making it a “robust and reliable” system that is “well suited to harsh environments and requires little maintenance.”
The 80X has an X-Y cutting travel of 4,064 mm x 2,032 mm (13 feet 4 inches x 6 feet 8 inches), and comes standard with OMAX Intelli-MAX® Premium Software, which runs on the Windows® XP operating system. Intelli-MAX can “calculate the precision of a tool path at over 2,000 points per inch, allowing for complete control over the motion of an abrasivejet, and enabling precise, rapid machining.”
MAXIEM - DualBRIDGE Systems
OMAX Corporation also manufactures the MAXIEM® line of JetCutting Centers, which recently offered its DualBRIDGE System option for larger MAXIEM machines to increase productivity and allow for greater flexibility.
“[This is] an option for select large-scale waterjets to increase machine capacity with two Y-bridges and up to four abrasive cutting heads,” states a company press release. “An operator can program the independent cutting heads to produce smaller parts or work in tandem to cut one large part. With this configuration, shops can also boost utilization rates since cutting can be performed while materials are loaded and unloaded from the machine.”
The MAXIEM’s two Y-bridges work independently from each other. This allows for “significantly increasing machine capacity” as each bridge can be optimized with completely different cutting head accessories.
MultiCam Inc. – V-Series WaterJet
MultiCam Inc.’s Value-Series WaterJet is based on offering its users a machine that combines a very affordable CNC investment and solid performance. This pure-water or abrasive cutting system features work surfaces up to 60” x 120”.
“We designed the V-Series WaterJet to make high performance, flexibility and productivity affordable,” says John Harris, MultiCam’s Director of Sales and Marketing. “This versatile machine cuts virtually any material in sheet form.”
The metered abrasive feeder/bulk hopper system operates under full CNC program control, full 360-degree rubberized bellows protect Y- and Z-axis bearings from abrasive garnet buildup, and steel covers keep X-axis precision bearing surfaces clean during the cutting process.
KMT’s durable and reliable NEOLine 40i intensifier rated at 40 hp and 55,000 PSI powers the V-Series WaterJet.
“Featuring a three-phase pump motor,” says Harris, “it provides superior performance with minimal maintenance.”
TECHNI Waterjet - Quantum Electric Servo Pump
TECHNI Waterjet’s Quantum Electro Server Pump (ESP) combines the advantages of direct-drive and intensifier pumps in a single product, says Chris McKinney, TECHNI’s National Sales Manager.
“It has an electric servomotor that drives plungers attached to a reciprocating ball screw and uses only the power required for the cutting process,” he says. “It is an almost silent operation with its 68dBA decibel level; small footprint - it is over 50 percent less
square-feet than an average hydraulic intensifier and lower profile and more ergonomic; and offers the unique ability to set varying output pressures, flow rates and power usage.”
He adds that the ESP is the only waterjet pump that uses only the power required for any given pressure and flow rate and that it advanced the efficiency advantages of direct-drive machines and eliminates the need to keep the motor running to ensure a continuous discharge of water to avoid damaging it.
“One no longer needs - when the cutting head is shut closed, to keep a relief valve running,” says McKinney. “Our clients want to reduce their electricity costs and we responded.”
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