(188187,6930,'_content_blocks_7_images_0_header','field_6170d8f49800f'),(188188,6930,'content_blocks_7_images_0_description',''),(188189,6930,'_content_blocks_7_images_0_description','field_6170d90398010'),(188190,6930,'content_blocks_7_images','1'),(188191,6930,'_content_blocks_7_images','field_6170d8df9800d'),(188192,6930,'content_blocks_8_header','Glass'),(188193,6930,'_content_blocks_8_header','field_6170d8ba9800b'),(188194,6930,'content_blocks_8_description','Intricate cutting and shaping of glass is easy with waterjet. The waterjet can generally drill all its own start holes, making it a highly versatile tool. Glass from 1/32\" to 10\" thick can be cut, even when laminated in multiple layers.'),(188195,6930,'_content_blocks_8_description','field_6170d8cd9800c'),(188196,6930,'content_blocks_8_images_0_image','2824'),(188197,6930,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(188198,6930,'content_blocks_8_images_0_header',''),(188199,6930,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(188200,6930,'content_blocks_8_images_0_description',''),(188201,6930,'_content_blocks_8_images_0_description','field_6170d90398010'),(188202,6930,'content_blocks_8_images','1'),(188203,6930,'_content_blocks_8_images','field_6170d8df9800d'),(188204,6930,'content_blocks_9_header','Waterjet in Any Industry'),(188205,6930,'_content_blocks_9_header','field_6170d8ba9800b'),(188206,6930,'content_blocks_9_description','The versatility of the waterjet allows it to be used in nearly every industry. There are many different materials that the waterjet can cut. Some of them have unique characteristics that require special attention when cutting. As you can see in the chart below each material you cut will have some unique characteristics that have to be taken into account.\r\n\r\nInsert 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quality waterjet university featured'),(188247,6935,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:4144;}}'),(188248,4144,'hefo_before','0'),(188249,4144,'hefo_after','0'),(188250,6936,'hero_gallery',''),(188251,6936,'_hero_gallery','field_60c23d554e4a3'),(188252,6936,'hero_banner','6935'),(188253,6936,'_hero_banner','field_6170dbe179470'),(188254,6936,'page_title','Overview'),(188255,6936,'_page_title','field_6170d88998008'),(188256,6936,'page_description','This chapter will discuss water quality requirements for high pressure waterjet cutting and why it is crucial to maintain proper water quality.\r\n\r\nNote: See \"Recommendation for water treatment\" at the end of this chapter for a potential solution to everything you are about to read in this chapter about water treatment.'),(188257,6936,'_page_description','field_6170d89398009'),(188258,6936,'content_blocks','11'),(188259,6936,'_content_blocks','field_6170d8ac9800a'),(188260,6936,'menu','37'),(188261,6936,'_menu','field_6170d9e059837'),(188262,6936,'display_left_column','1'),(188263,6936,'_display_left_column','field_613563c4d424b'),(188264,6936,'contact_left_heading',''),(188265,6936,'_contact_left_heading','field_60c249d645c99'),(188266,6936,'contact_left_copy',''),(188267,6936,'_contact_left_copy','field_60c24a0845c9c'),(188268,6936,'display_right_column','1'),(188269,6936,'_display_right_column','field_613563f4d424c'),(188270,6936,'contact_right_heading',''),(188271,6936,'_contact_right_heading','field_60c249e945c9a'),(188272,6936,'contact_right_copy',''),(188273,6936,'_contact_right_copy','field_60c249f845c9b'),(188274,6936,'contact_right_cta',''),(188275,6936,'_contact_right_cta','field_60c24a1945c9d'),(188276,6936,'content_blocks_0_header','Water Specifications'),(188277,6936,'_content_blocks_0_header','field_6170d8ba9800b'),(188278,6936,'content_blocks_0_description','Every manufacturer has specific requirements for water quality. Check with the manufacturer to get the specifications for your particular machine.\r\n\r\nThe water supplied to the intensifier is critical to waterjet cutting due to its direct influence on the service life of the equipment components such as check valves, seals and orifices. A high concentration of Total Dissolved Solids (TDS) causes accelerated wear of any components that come in contact with the high pressure water because of the increased abrasiveness of the water from the TDS.\r\n\r\nAs part of the installation planning, a water quality analysis should be performed by a commercial company that specializes in water conditioning equipment. The minimum information that should be supplied by this analysis is TDS, silica content and pH value. Companies like Culligan can perform these tests, or you can search \"water quality testing\" on the internet.\r\n\r\nInlet water should be treated for either the removal of hardness of the reduction of TDS. Water softening is an ion exchange process that removes scale forming minerals such as calcium. TDS reduction can be accomplished with either deionization (DI) or reverse osmosis equipment. Generally, DI or RO provides better component life than water softening.\r\n\r\nA water purification supplier should be consulted to supply the most suitable equipment for special conditions. It might be a good idea to ask any company that you are considering using if they have supplied systems for any other high pressure waterjet cutting systems and check their references.\r\n\r\nThe best treatment process for a specific application is a function of the original water quality and the desired service life of the affected components. Sixty to 70 ppm of TDS is optimum. Any water treatment producing TDS content of less than 0.5 part per million (ppm) should be avoided since the aggressiveness of such purified water will damage pump components.'),(188279,6936,'_content_blocks_0_description','field_6170d8cd9800c'),(188280,6936,'content_blocks_0_images',''),(188281,6936,'_content_blocks_0_images','field_6170d8df9800d'),(188282,6936,'content_blocks_1_header','Water Treatment Guidelines'),(188283,6936,'_content_blocks_1_header','field_6170d8ba9800b'),(188284,6936,'content_blocks_1_description','<table class=\"table table-bordered table-hover table-striped table-responsive\">\r\n<thead>\r\n<tr>\r\n<th>Criteria</th>\r\n<th>Values</th>\r\n<th>Recommended Treatment</th>\r\n</tr>\r\n</thead>\r\n<tbody>\r\n<tr>\r\n<td>Total Dissolved Solids (TDS)</td>\r\n<td>Low TDS (&lt;100 ppm)\r\nModerate TDS (100 - 200 ppm)\r\nHigh TDS (&gt;200 ppm)</td>\r\n<td>Good water, requires only softening\r\nCan be treated by softening, DI or RO\r\nPoor water, should be treated with RO or DI</td>\r\n</tr>\r\n<tr>\r\n<td>Silica Content</td>\r\n<td>High content (&gt;15 ppm)</td>\r\n<td>Dual Bed Strong Base DI</td>\r\n</tr>\r\n<tr>\r\n<td>pH Value</td>\r\n<td>Treated water must have a value of 6 - 8</td>\r\n</tr>\r\n</tbody>\r\n</table>'),(188285,6936,'_content_blocks_1_description','field_6170d8cd9800c'),(188286,6936,'content_blocks_1_images',''),(188287,6936,'_content_blocks_1_images','field_6170d8df9800d'),(188288,6936,'content_blocks_2_header','Suspended Solids'),(188289,6936,'_content_blocks_2_header','field_6170d8ba9800b'),(188290,6936,'content_blocks_2_description','In addition to the treatment described above, the water must be filtered for the removal of suspended solids. Different manufacturers supply differently sized final filters for this purpose, typically down to 0.45 nominal. See \"Recommendation for water treatment\" at the end of this chapter for an alternative to this.'),(188291,6936,'_content_blocks_2_description','field_6170d8cd9800c'),(188292,6936,'content_blocks_2_images',''),(188293,6936,'_content_blocks_2_images','field_6170d8df9800d'),(188294,6936,'content_blocks_3_header','Water Supply'),(188295,6936,'_content_blocks_3_header','field_6170d8ba9800b'),(188296,6936,'content_blocks_3_description','The initial water supply should be at least 5 gallons per minute at 40 pounds per square inch. The water may be boosted by a small pump to the 80 psi required by most intensifiers. Some intensifiers do not require pressure boosters, requiring only 30 psi for the incoming water. This removes a potential failure point from the system.'),(188297,6936,'_content_blocks_3_description','field_6170d8cd9800c'),(188298,6936,'content_blocks_3_images',''),(188299,6936,'_content_blocks_3_images','field_6170d8df9800d'),(188300,6936,'content_blocks_4_header','Hydraulic Oil Cooling'),(188301,6936,'_content_blocks_4_header','field_6170d8ba9800b'),(188302,6936,'content_blocks_4_description','Intensifier pumps have hydraulic oil that must be cooled. Typically there are three options:\r\n<ol>\r\n 	<li>Water-Cooled through a heat exchanger</li>\r\n 	<li>Air-Over-Oil Cooler</li>\r\n 	<li>Closed-Loop Chiller</li>\r\n</ol>'),(188303,6936,'_content_blocks_4_description','field_6170d8cd9800c'),(188304,6936,'content_blocks_4_images',''),(188305,6936,'_content_blocks_4_images','field_6170d8df9800d'),(188306,6936,'content_blocks_5_header','1. Heat exchanger - For water cooled pumps'),(188307,6936,'_content_blocks_5_header','field_6170d8ba9800b'),(188308,6936,'content_blocks_5_description','A heat exchanger is primarily used for cooling the hydraulic fluid of the intensifier pump. Typically the hydraulic oil temperature must be kept below 120° F (49° C). The heat exchanger will require a consistent water flow of 0 to 8 gpm (0 to 30 liters per minute) at an inlet temperature not exceeding 70° F in order to keep the hydraulic fluid at the proper temperature. Actual volume of water will depend on the pump selected. As many pumps are thermostatically controlled, when the pump is cool, it may be that no water is required.\r\n\r\nThis cooling water must go to drain. The cost of this water must be balanced against the costs of the other two cooling options (air-over-oil and chiller), which would not have any water going down the drain.\r\n\r\nPublic utility water is usually acceptable for cooling purposes. In situations where the water contains heavy mineral deposits, the exchanger tubes may eventually become restricted by particle buildup. If this is a chronic problem, pre-filtration and/or water softening may be necessary.\r\n\r\nDepending upon plant setup, ambient temperature can also be a factor in cooling the hydraulic fluid. Additional cooling may be required if the intensifier and/or heat exchanger is confined to a small, high-temperature space.'),(188309,6936,'_content_blocks_5_description','field_6170d8cd9800c'),(188310,6936,'content_blocks_5_images_0_image','4128'),(188311,6936,'_content_blocks_5_images_0_image','field_6170d8e99800e'),(188312,6936,'content_blocks_5_images_0_header',''),(188313,6936,'_content_blocks_5_images_0_header','field_6170d8f49800f'),(188314,6936,'content_blocks_5_images_0_description','Figure 1 - View of heat exchanger'),(188315,6936,'_content_blocks_5_images_0_description','field_6170d90398010'),(188316,6936,'content_blocks_5_images','1'),(188317,6936,'_content_blocks_5_images','field_6170d8df9800d'),(188318,6936,'content_blocks_6_header','2. Air-Over-Oil Cooler'),(188319,6936,'_content_blocks_6_header','field_6170d8ba9800b'),(188320,6936,'content_blocks_6_description','Some pumps will use an oil-air cooler to remove heat from the hydraulic oil, so no heat exchanger is required. In the summer, the unit can be vented outside the building to remove the heat from the building. In the winter it can be vented inside the building to help out with heating the building.'),(188321,6936,'_content_blocks_6_description','field_6170d8cd9800c'),(188322,6936,'content_blocks_6_images_0_image','4129'),(188323,6936,'_content_blocks_6_images_0_image','field_6170d8e99800e'),(188324,6936,'content_blocks_6_images_0_header',''),(188325,6936,'_content_blocks_6_images_0_header','field_6170d8f49800f'),(188326,6936,'content_blocks_6_images_0_description',''),(188327,6936,'_content_blocks_6_images_0_description','field_6170d90398010'),(188328,6936,'content_blocks_6_images','1'),(188329,6936,'_content_blocks_6_images','field_6170d8df9800d'),(188330,6936,'content_blocks_7_header','3. Chiller'),(188331,6936,'_content_blocks_7_header','field_6170d8ba9800b'),(188332,6936,'content_blocks_7_description','A chiller can be used to re-circulate the cooling water that is used by the intensifier\'s heat exchanger. It cools the water and then sends it through the heat exchanger again, creating a closed loop. A chiller is most effective in worth considering in a few situations in particular:\r\n<ul>\r\n 	<li>Warmer climates where the efficiency of the heat exchanger may be reduce</li>\r\n 	<li>Facilities that cannot send any water to a drain</li>\r\n 	<li>Parts of the country where there is a water shortage, or if the cost of water is high, because a 50 HP pump can use up to 5 gpm for cooling the hydraulics</li>\r\n</ul>\r\nThe chiller will only reuse the cooling water; you will still be putting approximately 1 gpm with a 50 hp pump of fresh water through the cutting head, which will not be reused with the chiller.\r\n\r\nIncoming water for the intensifier should also be maintained at 70° F (21° C) or cooler for best high pressure seal life. 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and Quality'),(188643,6954,'_page_title','field_6170d88998008'),(188644,6954,'page_description',''),(188645,6954,'_page_description','field_6170d89398009'),(188646,6954,'content_blocks_0_header','Overview'),(188647,6954,'_content_blocks_0_header','field_6170d8ba9800b'),(188648,6954,'content_blocks_0_description','For successful abrasive waterjet cutting, there are several factors at the cutting head that determine the precision and quality of the waterjet stream and will affect the quality of part you are able to cut with an abrasive waterjet. There are other factors that will go into cutting a precise and accurate part (machine design, controls, software and high-pressure pump) that will be discussed in other chapters. This chapter will focus on the cutting head and the waterjet as it interacts with the work piece.'),(188649,6954,'_content_blocks_0_description','field_6170d8cd9800c'),(188650,6954,'content_blocks_0_images',''),(188651,6954,'_content_blocks_0_images','field_6170d8df9800d'),(188652,6954,'content_blocks_1_header','Factors affecting precision & quality'),(188653,6954,'_content_blocks_1_header','field_6170d8ba9800b'),(188654,6954,'content_blocks_1_description','Figure 1 - Abrasive and Water Only Waterjet Cutting Heads'),(188655,6954,'_content_blocks_1_description','field_6170d8cd9800c'),(188656,6954,'content_blocks_1_images_0_image','2830'),(188657,6954,'_content_blocks_1_images_0_image','field_6170d8e99800e'),(188658,6954,'content_blocks_1_images_0_header',''),(188659,6954,'_content_blocks_1_images_0_header','field_6170d8f49800f'),(188660,6954,'content_blocks_1_images_0_description',''),(188661,6954,'_content_blocks_1_images_0_description','field_6170d90398010'),(188662,6954,'content_blocks_1_images_1_image','2831'),(188663,6954,'_content_blocks_1_images_1_image','field_6170d8e99800e'),(188664,6954,'content_blocks_1_images_1_header',''),(188665,6954,'_content_blocks_1_images_1_header','field_6170d8f49800f'),(188666,6954,'content_blocks_1_images_1_description',''),(188667,6954,'_content_blocks_1_images_1_description','field_6170d90398010'),(188668,6954,'content_blocks_1_images','2'),(188669,6954,'_content_blocks_1_images','field_6170d8df9800d'),(188670,6954,'content_blocks_2_header','1 - Abrasive mixing tube length'),(188671,6954,'_content_blocks_2_header','field_6170d8ba9800b'),(188672,6954,'content_blocks_2_description','A longer abrasive mixing tube (a.k.a. abrasive nozzle) produces a more coherent waterjet stream. The optimum mixing tube length is 3\" - 4\" (75 mm - 100 mm).'),(188673,6954,'_content_blocks_2_description','field_6170d8cd9800c'),(188674,6954,'content_blocks_2_images',''),(188675,6954,'_content_blocks_2_images','field_6170d8df9800d'),(188676,6954,'content_blocks_3_header','2 - Alignment of components'),(188677,6954,'_content_blocks_3_header','field_6170d8ba9800b'),(188678,6954,'content_blocks_3_description','The orifice, mixing chamber and abrasive nozzle must be precisely machined and fit perfectly together to avoid damage of consumables by the waterjet stream.'),(188679,6954,'_content_blocks_3_description','field_6170d8cd9800c'),(188680,6954,'content_blocks_3_images',''),(188681,6954,'_content_blocks_3_images','field_6170d8df9800d'),(188682,6954,'content_blocks_4_header','3 - Precise orifice'),(188683,6954,'_content_blocks_4_header','field_6170d8ba9800b'),(188684,6954,'content_blocks_4_description','The inside of the abrasive nozzle must be machined to ensure perfect alignment with the waterjet stream. See \"Waterjet stream\'s effect on accuracy\" section of this chapter for more information.'),(188685,6954,'_content_blocks_4_description','field_6170d8cd9800c'),(188686,6954,'content_blocks_4_images',''),(188687,6954,'_content_blocks_4_images','field_6170d8df9800d'),(188688,6954,'content_blocks_5_header','4 - Diameter of stream'),(188689,6954,'_content_blocks_5_header','field_6170d8ba9800b'),(188690,6954,'content_blocks_5_description','A small diameter waterjet stream, as produced by a .010\" (0.25 mm) orifice produces an efficient, high-quality stream. As a trade-off, cutting speeds are slower than when using a 0.014\" (0.36 mm) or larger orifice, since less water and abrasive are used. See Chapter 2 \"Relationship Parameters\" for more information on orifice selection.'),(188691,6954,'_content_blocks_5_description','field_6170d8cd9800c'),(188692,6954,'content_blocks_5_images',''),(188693,6954,'_content_blocks_5_images','field_6170d8df9800d'),(188694,6954,'content_blocks_6_header','5 - Low, controlled stand-off from work'),(188695,6954,'_content_blocks_6_header','field_6170d8ba9800b'),(188696,6954,'content_blocks_6_description','Maintaining a close distance between the nozzle and the work piece, between 0.040\" and 0.060\" (1.0 - 1.5 mm), is critical for producing accurate parts while also getting the maximum efficiency from the waterjet. Cutting closer to the material limits the amount of atmosphere that the jet has to travel through before reaching the work piece. This limits the expansion of the waterjet stream, since as the jet expands, the effective power of the jet is reduced. Cutting speeds will need to be reduced to compensate. If the distance between the nozzle and the work piece is increased by ¼\", cutting speeds must be reduced by approximately 20% to achieve similar results with respect to tolerance and edge quality. Cutting under water with CNC height control will allow for ultimate control of the waterjet stream.\r\n\r\nSee effect of nozzle height below for more information.'),(188697,6954,'_content_blocks_6_description','field_6170d8cd9800c'),(188698,6954,'content_blocks_6_images',''),(188699,6954,'_content_blocks_6_images','field_6170d8df9800d'),(188700,6954,'content_blocks_7_header','Creation of the abrasive waterjet stream'),(188701,6954,'_content_blocks_7_header','field_6170d8ba9800b'),(188702,6954,'content_blocks_7_description','Following is a description of how the abrasive waterjet stream is created in the cutting head. The numbers indicated below refer to the numbers in Figure 2.'),(188703,6954,'_content_blocks_7_description','field_6170d8cd9800c'),(188704,6954,'content_blocks_7_images_0_image','2831'),(188705,6954,'_content_blocks_7_images_0_image','field_6170d8e99800e'),(188706,6954,'content_blocks_7_images_0_header',''),(188707,6954,'_content_blocks_7_images_0_header','field_6170d8f49800f'),(188708,6954,'content_blocks_7_images_0_description',''),(188709,6954,'_content_blocks_7_images_0_description','field_6170d90398010'),(188710,6954,'content_blocks_7_images','1'),(188711,6954,'_content_blocks_7_images','field_6170d8df9800d'),(188712,6954,'content_blocks_8_header','1 - Water Pressure'),(188713,6954,'_content_blocks_8_header','field_6170d8ba9800b'),(188714,6954,'content_blocks_8_description','Water pressurized at 50,000 psi or greater enters the cutting head at relatively slow speed, in the order of a few feet per second. (See \"How It Works\" for more information on how this water pressure is created and transmitted to the cutting head.)'),(188715,6954,'_content_blocks_8_description','field_6170d8cd9800c'),(188716,6954,'content_blocks_8_images',''),(188717,6954,'_content_blocks_8_images','field_6170d8df9800d'),(188718,6954,'content_blocks_9_header','Stream Conversion'),(188719,6954,'_content_blocks_9_header','field_6170d8ba9800b'),(188720,6954,'content_blocks_9_description','The water is forced through an orifice that has a small diameter orifice, anywhere from 0.004\" to 0.045\" depending upon the application. These orifices are made of extremely hard material, such as diamond, sapphire or ruby. This step converts the water stream from a high pressure stream to a high velocity stream. At this point the water is moving in excess of 2200 miles per hour (3657 kilometers per hour).'),(188721,6954,'_content_blocks_9_description','field_6170d8cd9800c'),(188722,6954,'content_blocks_9_images',''),(188723,6954,'_content_blocks_9_images','field_6170d8df9800d'),(188724,6954,'content_blocks_10_header','3 - Venturi Effect'),(188725,6954,'_content_blocks_10_header','field_6170d8ba9800b'),(188726,6954,'content_blocks_10_description','The high velocity of the jet creates a Venturi effect, or vacuum, in the mixing chamber located immediately beneath the orifice. Abrasive, typically garnet, is metered from a mini-hopper through a plastic tube down to the cutting head and is sucked into the waterjet stream in the mixing chamber. Cutting speed will increase with more abrasive until a saturation point is reached where speed starts to decrease. If the abrasive amount is increased too high, ultimately the mixing tube will clog.\r\nOne of the exciting advancements in waterjet cutting in the past few years is the appearance on CNC- controlled abrasive metering systems. These systems precisely control the amount of abrasive that is allowed to flow to the cutting head. During the piercing process, cutting pressure and abrasive amount are reduced and the cutting head makes small, circular motions in the X and Y axes. This piercing procedure allows for difficult applications, such as piercing of glass and stone, to be processed with relative ease.'),(188727,6954,'_content_blocks_10_description','field_6170d8cd9800c'),(188728,6954,'content_blocks_10_images',''),(188729,6954,'_content_blocks_10_images','field_6170d8df9800d'),(188730,6954,'content_blocks_11_header','4 - Waterjet stream & abrasive mixture'),(188731,6954,'_content_blocks_11_header','field_6170d8ba9800b'),(188732,6954,'content_blocks_11_description','The abrasive is fully mixed in the waterjet stream and is accelerated to approximately the speed of the waterjet stream. This step does steal some energy from the waterjet stream, slowing it down slightly.'),(188733,6954,'_content_blocks_11_description','field_6170d8cd9800c'),(188734,6954,'content_blocks_11_images',''),(188735,6954,'_content_blocks_11_images','field_6170d8df9800d'),(188736,6954,'content_blocks_12_header','5 - Accelerated Erosion'),(188737,6954,'_content_blocks_12_header','field_6170d8ba9800b'),(188738,6954,'content_blocks_12_description','The abrasive waterjet stream exits the mixing tube with extreme speed and power. The abrasive erodes the material to be cut. The process is referred to as \"abrasive waterjet cutting\" because it is the abrasive that is actually doing the cutting. The water\'s role is simply to give speed and power to the abrasive. In pure waterjet cutting, used for soft materials like foam and food, the force of the waterjet stream alone is enough to cut the material and abrasive is not required.'),(188739,6954,'_content_blocks_12_description','field_6170d8cd9800c'),(188740,6954,'content_blocks_12_images',''),(188741,6954,'_content_blocks_12_images','field_6170d8df9800d'),(188742,6954,'content_blocks_13_header','Affect of speed upon kerf angle'),(188743,6954,'_content_blocks_13_header','field_6170d8ba9800b'),(188744,6954,'content_blocks_13_description','Kerf angle, or bevel, refers to the dimensional difference between the top and bottom of the cut cross-section. Cutting too fast will result in a wider kerf width at the top of the cut cross-section and a narrower kerf width at the bottom of the zone. In Fig. 3, from left to right, cuts were done at 26 inches per minute (ipm), 14 ipm and 9.7 ipm (660 millimeters per minute [mm/min], 355 mm/min and 246 mm/min). All other parameters were held constant (pressure 60 kpsi, 0.060\" standoff distance, 1.3 lb/min abrasive [4134 bar, 1.5mm and 600 grams/min]). At the top of the cut, kerf width was similar, around 0.044\" (1.12 mm). The difference between top and bottom going from left to right was 0.017\", 0.013\" and 0.011\" (0.43 mm, 0.33 mm and 0.28 mm). This shows the decrease in angularity as speed decreases.\r\n\r\nFigure 3 - 3/4\" (20 mm) Aluminum with 3 different cut speeds'),(188745,6954,'_content_blocks_13_description','field_6170d8cd9800c'),(188746,6954,'content_blocks_13_images_0_image','2832'),(188747,6954,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(188748,6954,'content_blocks_13_images_0_header','High Speed, Widest Kerf at Top, Narrowest aat Bottom'),(188749,6954,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(188750,6954,'content_blocks_13_images_0_description',''),(188751,6954,'_content_blocks_13_images_0_description','field_6170d90398010'),(188752,6954,'content_blocks_13_images_1_image','2833'),(188753,6954,'_content_blocks_13_images_1_image','field_6170d8e99800e'),(188754,6954,'content_blocks_13_images_1_header','Medium Speed, Wider Kerf width at top than at bottom'),(188755,6954,'_content_blocks_13_images_1_header','field_6170d8f49800f'),(188756,6954,'content_blocks_13_images_1_description',''),(188757,6954,'_content_blocks_13_images_1_description','field_6170d90398010'),(188758,6954,'content_blocks_13_images_2_image','2834'),(188759,6954,'_content_blocks_13_images_2_image','field_6170d8e99800e'),(188760,6954,'content_blocks_13_images_2_header','Slower Speed, Similar width Kerf at top and bottom'),(188761,6954,'_content_blocks_13_images_2_header','field_6170d8f49800f'),(188762,6954,'content_blocks_13_images_2_description',''),(188763,6954,'_content_blocks_13_images_2_description','field_6170d90398010'),(188764,6954,'content_blocks_13_images','3'),(188765,6954,'_content_blocks_13_images','field_6170d8df9800d'),(188766,6954,'content_blocks_14_header',''),(188767,6954,'_content_blocks_14_header','field_6170d8ba9800b'),(188768,6954,'content_blocks_14_description','The picture below shows one additional cut that was done extremely slowly (1 ipm or 25.4 mm/min) to demonstrate that when speed is decreased enough, the kerf width at the bottom of the part will be larger than at the top. In this example the kerf width at the bottom was 0.014\" (0.36 mm) larger than at the top.'),(188769,6954,'_content_blocks_14_description','field_6170d8cd9800c'),(188770,6954,'content_blocks_14_images_0_image','2835'),(188771,6954,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(188772,6954,'content_blocks_14_images_0_header','Very slow speed, Narrower kerf width at top, Wider at Bottom'),(188773,6954,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(188774,6954,'content_blocks_14_images_0_description',''),(188775,6954,'_content_blocks_14_images_0_description','field_6170d90398010'),(188776,6954,'content_blocks_14_images','1'),(188777,6954,'_content_blocks_14_images','field_6170d8df9800d'),(188778,6954,'content_blocks','22'),(188779,6954,'_content_blocks','field_6170d8ac9800a'),(188780,6954,'menu','37'),(188781,6954,'_menu','field_6170d9e059837'),(188782,6954,'display_left_column','1'),(188783,6954,'_display_left_column','field_613563c4d424b'),(188784,6954,'contact_left_heading',''),(188785,6954,'_contact_left_heading','field_60c249d645c99'),(188786,6954,'contact_left_copy',''),(188787,6954,'_contact_left_copy','field_60c24a0845c9c'),(188788,6954,'display_right_column','1'),(188789,6954,'_display_right_column','field_613563f4d424c'),(188790,6954,'contact_right_heading',''),(188791,6954,'_contact_right_heading','field_60c249e945c9a'),(188792,6954,'contact_right_copy',''),(188793,6954,'_contact_right_copy','field_60c249f845c9b'),(188794,6954,'contact_right_cta',''),(188795,6954,'_contact_right_cta','field_60c24a1945c9d'),(188796,6954,'content_blocks_15_header','Drag of waterjet stream and cut quality'),(188797,6954,'_content_blocks_15_header','field_6170d8ba9800b'),(188798,6954,'content_blocks_15_description','Increasing feedrate results in increased trail back of waterjet stream. This concept is shown in Figure 5 below. Rougher edge quality is the result of more shearing action versus erosion action of abrasive at slower speeds. Modern controllers allow the user to adjust cut quality based upon part requirements. High-precision holes can be cut slower for a smoother, straighter cut. Faster cutting speeds with rougher edge quality can be used on less critical areas.'),(188799,6954,'_content_blocks_15_description','field_6170d8cd9800c'),(188800,6954,'content_blocks_15_images_0_image',''),(188801,6954,'_content_blocks_15_images_0_image','field_6170d8e99800e'),(188802,6954,'content_blocks_15_images_0_header','Seperation Cut'),(188803,6954,'_content_blocks_15_images_0_header','field_6170d8f49800f'),(188804,6954,'content_blocks_15_images_0_description',''),(188805,6954,'_content_blocks_15_images_0_description','field_6170d90398010'),(188806,6954,'content_blocks_15_images_1_image',''),(188807,6954,'_content_blocks_15_images_1_image','field_6170d8e99800e'),(188808,6954,'content_blocks_15_images_1_header','Through Cut'),(188809,6954,'_content_blocks_15_images_1_header','field_6170d8f49800f'),(188810,6954,'content_blocks_15_images_1_description',''),(188811,6954,'_content_blocks_15_images_1_description','field_6170d90398010'),(188812,6954,'content_blocks_15_images_2_image',''),(188813,6954,'_content_blocks_15_images_2_image','field_6170d8e99800e'),(188814,6954,'content_blocks_15_images_2_header','Clean Cut ± 0.010\"'),(188815,6954,'_content_blocks_15_images_2_header','field_6170d8f49800f'),(188816,6954,'content_blocks_15_images_2_description',''),(188817,6954,'_content_blocks_15_images_2_description','field_6170d90398010'),(188818,6954,'content_blocks_15_images_3_image',''),(188819,6954,'_content_blocks_15_images_3_image','field_6170d8e99800e'),(188820,6954,'content_blocks_15_images_3_header','Good Finish'),(188821,6954,'_content_blocks_15_images_3_header','field_6170d8f49800f'),(188822,6954,'content_blocks_15_images_3_description',''),(188823,6954,'_content_blocks_15_images_3_description','field_6170d90398010'),(188824,6954,'content_blocks_15_images_4_image',''),(188825,6954,'_content_blocks_15_images_4_image','field_6170d8e99800e'),(188826,6954,'content_blocks_15_images_4_header','Excellent Finish ± 0.005\"'),(188827,6954,'_content_blocks_15_images_4_header','field_6170d8f49800f'),(188828,6954,'content_blocks_15_images_4_description',''),(188829,6954,'_content_blocks_15_images_4_description','field_6170d90398010'),(188830,6954,'content_blocks_15_images','5'),(188831,6954,'_content_blocks_15_images','field_6170d8df9800d'),(188832,6954,'content_blocks_16_header','Effect of Nozzle Height'),(188833,6954,'_content_blocks_16_header','field_6170d8ba9800b'),(188834,6954,'content_blocks_16_description','For best cut quality, an optimum distance between the nozzle and the work piece should be maintained. Typically, between 0.0625\" and 0.125\" (1.5 – 3.0 mm) is the optimum height for abrasive waterjet cutting. As the distance increases above 0.125\", rounding on the top edge of the cut will result. This occurs because the waterjet stream looses coherence as it travels through open air. Increased nozzle height will also result in increased kerf angle. If the distance between the nozzle and the work piece is increased by ¼\", cutting speeds must be reduced by approximately 20% to achieve similar results with respect to tolerance and edge quality. Automatic height control is the most reliable and accurate way to maintain proper standoff distance. Figure 7 shows that if the nozzle height is increased too far, the jet will not have enough power to fully penetrate material that it would easily cut at much lower heights.'),(188835,6954,'_content_blocks_16_description','field_6170d8cd9800c'),(188836,6954,'content_blocks_16_images_0_image','2838'),(188837,6954,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(188838,6954,'content_blocks_16_images_0_header',''),(188839,6954,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(188840,6954,'content_blocks_16_images_0_description','Figure 6 - 3/4\" Aluminum with cuts at various nozzle heights, same speed'),(188841,6954,'_content_blocks_16_images_0_description','field_6170d90398010'),(188842,6954,'content_blocks_16_images_1_image','2839'),(188843,6954,'_content_blocks_16_images_1_image','field_6170d8e99800e'),(188844,6954,'content_blocks_16_images_1_header',''),(188845,6954,'_content_blocks_16_images_1_header','field_6170d8f49800f'),(188846,6954,'content_blocks_16_images_1_description','Figure 7 - Increasing nozzle height to point of no jet penetration'),(188847,6954,'_content_blocks_16_images_1_description','field_6170d90398010'),(188848,6954,'content_blocks_16_images','2'),(188849,6954,'_content_blocks_16_images','field_6170d8df9800d'),(188850,6954,'content_blocks_17_header','Effect of speed on inside corners'),(188851,6954,'_content_blocks_17_header','field_6170d8ba9800b'),(188852,6954,'content_blocks_17_description','Since the waterjet is a non-rigid cutting tool, inside corners on parts can exhibit a certain amount of overcut on the bottom, or exit, side of the part. This can be reduced by decelerating into the corner and slowly accelerating, allowing the bottom portion of the jet to catch up with the top portion around the corner. The waterjet control must have the ability to do this automatically.'),(188853,6954,'_content_blocks_17_description','field_6170d8cd9800c'),(188854,6954,'content_blocks_17_images_0_image',''),(188855,6954,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(188856,6954,'content_blocks_17_images_0_header','missing Images'),(188857,6954,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(188858,6954,'content_blocks_17_images_0_description',''),(188859,6954,'_content_blocks_17_images_0_description','field_6170d90398010'),(188860,6954,'content_blocks_17_images','1'),(188861,6954,'_content_blocks_17_images','field_6170d8df9800d'),(188862,6954,'content_blocks_18_header','Tight radii'),(188863,6954,'_content_blocks_18_header','field_6170d8ba9800b'),(188864,6954,'content_blocks_18_description','Since the waterjet stream is a round tool, with a diameter between 0.030\" and 0.040\" (0.76 mm and 1.02 mm) for abrasive waterjet cutting, creating any inside corner that is perfectly square is impossible. CAM software will typically read geometries and give a user the option to automatically place a very small radius on these corners. This will avoid damaging the part and reduce processing time, as radii are faster to cut than square corners. For very acute angles, the actual part that is cut may differ significantly from the original drawing and should be considered for form, fit and function before processing.'),(188865,6954,'_content_blocks_18_description','field_6170d8cd9800c'),(188866,6954,'content_blocks_18_images_0_image','2840'),(188867,6954,'_content_blocks_18_images_0_image','field_6170d8e99800e'),(188868,6954,'content_blocks_18_images_0_header',''),(188869,6954,'_content_blocks_18_images_0_header','field_6170d8f49800f'),(188870,6954,'content_blocks_18_images_0_description',''),(188871,6954,'_content_blocks_18_images_0_description','field_6170d90398010'),(188872,6954,'content_blocks_18_images','1'),(188873,6954,'_content_blocks_18_images','field_6170d8df9800d'),(188874,6954,'content_blocks_19_header','Lead-in and Lead-out types'),(188875,6954,'_content_blocks_19_header','field_6170d8ba9800b'),(188876,6954,'content_blocks_19_description','Piercing in the scrap area of material and \"leading-in\" to the actual geometry to cut is standard operating procedure in most waterjet applications. This avoids placing a large blow-out blemish from the initial piercing on the surface of the part. At the end of a cut, a lead-out may be required to remove any \"nib\" from the lead-in area.\r\n\r\nVarious types of lead-ins and lead-outs can be experimented with for different materials and thicknesses. Figure 9 shows a few examples of lead-ins and leads-outs.'),(188877,6954,'_content_blocks_19_description','field_6170d8cd9800c'),(188878,6954,'content_blocks_19_images_0_image','2842'),(188879,6954,'_content_blocks_19_images_0_image','field_6170d8e99800e'),(188880,6954,'content_blocks_19_images_0_header','Different lead-in/lead-out types'),(188881,6954,'_content_blocks_19_images_0_header','field_6170d8f49800f'),(188882,6954,'content_blocks_19_images_0_description','Number 1 (straight line lead-in with very short straight line lead-out) is desirable for any sharp corner.\r\n\r\nNumber 2 (arc lead-in with short arc lead-out) is good for thinner and softer materials.\r\n\r\nNumber 3 (straight line lead in with no lead-out) gives good results on thicker, harder material.\r\n\r\nNumber 4 is an example of a straight line lead in with short arc lead-out. CAM software should have the flexibility to combine different types of lead-ins and lead-outs should the user wish to experiment.'),(188883,6954,'_content_blocks_19_images_0_description','field_6170d90398010'),(188884,6954,'content_blocks_19_images','1'),(188885,6954,'_content_blocks_19_images','field_6170d8df9800d'),(188886,6954,'content_blocks_20_header','Reducing lead-in/lead-out witness marks'),(188887,6954,'_content_blocks_20_header','field_6170d8ba9800b'),(188888,6954,'content_blocks_20_description','At the end of a cut, a small nib may remain on the bottom portion of the cut in the lead-in/lead-out area. Because of the lagging effect discussed previously, when the jet reaches the end of the cut, the top portion of the jet will find the path of least resistance, and effectively \"jump over\" a small bit of material leaving a nib. With the more sophisticated controls and software available today, this can be reduced by decelerating at the end of the cut to allow the bottom portion of the jet to catch up with the top before reaching the end of the cut. Figure 10 below shows examples of a large nib because of too much speed at the end of a cut and an example of a minimal witness mark with appropriate slow down at the end of the cut.'),(188889,6954,'_content_blocks_20_description','field_6170d8cd9800c'),(188890,6954,'content_blocks_20_images_0_image','2843'),(188891,6954,'_content_blocks_20_images_0_image','field_6170d8e99800e'),(188892,6954,'content_blocks_20_images_0_header','Bad part on left showing excessive nib.'),(188893,6954,'_content_blocks_20_images_0_header','field_6170d8f49800f'),(188894,6954,'content_blocks_20_images_0_description',''),(188895,6954,'_content_blocks_20_images_0_description','field_6170d90398010'),(188896,6954,'content_blocks_20_images_1_image','2844'),(188897,6954,'_content_blocks_20_images_1_image','field_6170d8e99800e'),(188898,6954,'content_blocks_20_images_1_header','Good part on right with minimal witness mark'),(188899,6954,'_content_blocks_20_images_1_header','field_6170d8f49800f'),(188900,6954,'content_blocks_20_images_1_description',''),(188901,6954,'_content_blocks_20_images_1_description','field_6170d90398010'),(188902,6954,'content_blocks_20_images','2'),(188903,6954,'_content_blocks_20_images','field_6170d8df9800d'),(188904,6954,'content_blocks_21_header','Waterjet stream\'s effect on accuracy'),(188905,6954,'_content_blocks_21_header','field_6170d8ba9800b'),(188906,6954,'content_blocks_21_description','Mixing tubes are made of extremely hard materials such as sintered boride or more commonly composite tungsten carbide. However, the nozzles are subject to wear and their cost must be taken into consideration for job costing. The orifice of a mixing tube will typically increase in diameter by about 0.0001\" per hour of cutting because of the erosion of the abrasive flowing through the nozzle. If this wear occurs in an even fashion, up to 120 hours of cutting can be realized with a nozzle. The biggest factor affecting nozzle wear is the material from which they are made. Controls allow for compensating for this wear by allowing the operator to change the tool offset.\r\n\r\nIf the wear of the nozzle is not symmetrical, the waterjet stream will also not be round. This will result in wider tolerances when cutting in a certain direction.\r\n\r\nThe tolerance requirements of a job will dictate the actual number of hours a user can expect from a nozzle. The nozzle can, of course, be set aside and used later for looser tolerance jobs. Control software should allow the ability to track hours on individual components to make consumable management easier. See Figure 12 below for an example of orifice and mixing tube tracking.'),(188907,6954,'_content_blocks_21_description','field_6170d8cd9800c'),(188908,6954,'content_blocks_21_images_0_image',''),(188909,6954,'_content_blocks_21_images_0_image','field_6170d8e99800e'),(188910,6954,'content_blocks_21_images_0_header','Need Image'),(188911,6954,'_content_blocks_21_images_0_header','field_6170d8f49800f'),(188912,6954,'content_blocks_21_images_0_description',''),(188913,6954,'_content_blocks_21_images_0_description','field_6170d90398010'),(188914,6954,'content_blocks_21_images_1_image','2845'),(188915,6954,'_content_blocks_21_images_1_image','field_6170d8e99800e'),(188916,6954,'content_blocks_21_images_1_header','Orifice on right is off-center.'),(188917,6954,'_content_blocks_21_images_1_header','field_6170d8f49800f'),(188918,6954,'content_blocks_21_images_1_description',''),(188919,6954,'_content_blocks_21_images_1_description','field_6170d90398010'),(188920,6954,'content_blocks_21_images','2'),(188921,6954,'_content_blocks_21_images','field_6170d8df9800d'),(188923,2848,'hefo_before','0'),(188924,2848,'hefo_after','0'),(188925,6955,'hero_gallery',''),(188926,6955,'_hero_gallery','field_60c23d554e4a3'),(188927,6955,'hero_banner','6933'),(188928,6955,'_hero_banner','field_6170dbe179470'),(188929,6955,'page_title','Nozzle and Orifice'),(188930,6955,'_page_title','field_6170d88998008'),(188931,6955,'page_description','This section will focus on relationships between speed and edge quality, pump size, water nozzle and abrasive nozzle selection, maximum number of cutting heads and how some of these parameters can change over time.'),(188932,6955,'_page_description','field_6170d89398009'),(188933,6955,'content_blocks_0_header','Desired edge quality'),(188934,6955,'_content_blocks_0_header','field_6170d8ba9800b'),(188935,6955,'content_blocks_0_description','Edge quality is defined with the numbers 1 through 5. Lower numbers indicate rougher edge finish; higher numbers are smoother. For thin materials, the difference in cutting speed for Quality 1 could be as much as 3 times faster than the speed for Quality 5. For thicker materials, Quality 1 could be 6 times faster than Quality 5. For example, 4” thick Aluminum Q5 would be 0.72 ipm (18 mm/min) and Q1 would be 4.2 ipm (107 mm/min), 5.8 times faster.'),(188936,6955,'_content_blocks_0_description','field_6170d8cd9800c'),(188937,6955,'content_blocks_0_images_0_image','2950'),(188938,6955,'_content_blocks_0_images_0_image','field_6170d8e99800e'),(188939,6955,'content_blocks_0_images_0_header','Seperation Cut'),(188940,6955,'_content_blocks_0_images_0_header','field_6170d8f49800f'),(188941,6955,'content_blocks_0_images_0_description',''),(188942,6955,'_content_blocks_0_images_0_description','field_6170d90398010'),(188943,6955,'content_blocks_0_images_1_image','2951'),(188944,6955,'_content_blocks_0_images_1_image','field_6170d8e99800e'),(188945,6955,'content_blocks_0_images_1_header','Through Cut'),(188946,6955,'_content_blocks_0_images_1_header','field_6170d8f49800f'),(188947,6955,'content_blocks_0_images_1_description',''),(188948,6955,'_content_blocks_0_images_1_description','field_6170d90398010'),(188949,6955,'content_blocks_0_images_2_image','2952'),(188950,6955,'_content_blocks_0_images_2_image','field_6170d8e99800e'),(188951,6955,'content_blocks_0_images_2_header','Clean Cut ± 0.010\"'),(188952,6955,'_content_blocks_0_images_2_header','field_6170d8f49800f'),(188953,6955,'content_blocks_0_images_2_description',''),(188954,6955,'_content_blocks_0_images_2_description','field_6170d90398010'),(188955,6955,'content_blocks_0_images_3_image','2953'),(188956,6955,'_content_blocks_0_images_3_image','field_6170d8e99800e'),(188957,6955,'content_blocks_0_images_3_header','Good Finish'),(188958,6955,'_content_blocks_0_images_3_header','field_6170d8f49800f'),(188959,6955,'content_blocks_0_images_3_description',''),(188960,6955,'_content_blocks_0_images_3_description','field_6170d90398010'),(188961,6955,'content_blocks_0_images_4_image','2954'),(188962,6955,'_content_blocks_0_images_4_image','field_6170d8e99800e'),(188963,6955,'content_blocks_0_images_4_header','Excellent Finish ± 0.005\"'),(188964,6955,'_content_blocks_0_images_4_header','field_6170d8f49800f'),(188965,6955,'content_blocks_0_images_4_description',''),(188966,6955,'_content_blocks_0_images_4_description','field_6170d90398010'),(188967,6955,'content_blocks_0_images','5'),(188968,6955,'_content_blocks_0_images','field_6170d8df9800d'),(188969,6955,'content_blocks_1_header','Pump Specification'),(188970,6955,'_content_blocks_1_header','field_6170d8ba9800b'),(188971,6955,'content_blocks_1_description','Every waterjet company will be able to supply a chart similar to the following showing the horsepower, maximum pressure and maximum water output for the pumps offered with their systems.'),(188972,6955,'_content_blocks_1_description','field_6170d8cd9800c'),(188973,6955,'content_blocks_1_images_0_image',''),(188974,6955,'_content_blocks_1_images_0_image','field_6170d8e99800e'),(188975,6955,'content_blocks_1_images_0_header',''),(188976,6955,'_content_blocks_1_images_0_header','field_6170d8f49800f'),(188977,6955,'content_blocks_1_images_0_description',''),(188978,6955,'_content_blocks_1_images_0_description','field_6170d90398010'),(188979,6955,'content_blocks_1_images','1'),(188980,6955,'_content_blocks_1_images','field_6170d8df9800d'),(188981,6955,'content_blocks_2_header','Horsepower, pressure and water output'),(188982,6955,'_content_blocks_2_header','field_6170d8ba9800b'),(188983,6955,'content_blocks_2_description','In order to achieve a required edge quality, cutting speed, tolerance and production requirement in a cost-effective manner, understanding the relationship amongst horsepower, pressure and water output is vital. These factors will determine the maximum size orifice you will be able to use, the maximum number of cutting heads you will be able to run, what speeds you will be able to cut at and the maximum thickness you will be able to cut cost effectively.'),(188984,6955,'_content_blocks_2_description','field_6170d8cd9800c'),(188985,6955,'content_blocks_2_images',''),(188986,6955,'_content_blocks_2_images','field_6170d8df9800d'),(188987,6955,'content_blocks_3_header','Horsepower'),(188988,6955,'_content_blocks_3_header','field_6170d8ba9800b'),(188989,6955,'content_blocks_3_description','Waterjet pumps are specified in either horsepower (HP) or kilowatts (kW) to indicate the size of the electric motor that creates the force to pressurize the water. Engineers will size the hydraulic motor depending upon the water pressure and water output they are trying to achieve.\r\n\r\nThe most common pumps seen on the market today are intensifier style pumps. A simplified diagram of the intensifier concept is shown below. The pumps use hydraulics to apply a certain amount of oil pressure on one side of a piston of a certain diameter. On the water side of the pump, the diameter of the piston is much smaller. The difference in the surface area between the hydraulic side and the water side gives a multiplication factor, or intensification, to the pressure from the oil side. Most intensifier pumps have an intensification ratio of 20 times. This design will be explained in more detail in the “How it Works” chapter.'),(188990,6955,'_content_blocks_3_description','field_6170d8cd9800c'),(188991,6955,'content_blocks_3_images_0_image','2849'),(188992,6955,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(188993,6955,'content_blocks_3_images_0_header',''),(188994,6955,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(188995,6955,'content_blocks_3_images_0_description',''),(188996,6955,'_content_blocks_3_images_0_description','field_6170d90398010'),(188997,6955,'content_blocks_3_images','1'),(188998,6955,'_content_blocks_3_images','field_6170d8df9800d'),(188999,6955,'content_blocks_4_header',''),(189000,6955,'_content_blocks_4_header','field_6170d8ba9800b'),(189001,6955,'content_blocks_4_description','Another style pump sometimes used on waterjets is the direct drive pump. This pump uses an electric motor to turn a crankshaft that moves three or more pistons that create the water pressure, very similar to a car engine. Faster revolutions of the motor create higher pressure and more water volume. The basic concept for the direct drive is shown below.'),(189002,6955,'_content_blocks_4_description','field_6170d8cd9800c'),(189003,6955,'content_blocks_4_images_0_image','2850'),(189004,6955,'_content_blocks_4_images_0_image','field_6170d8e99800e'),(189005,6955,'content_blocks_4_images_0_header',''),(189006,6955,'_content_blocks_4_images_0_header','field_6170d8f49800f'),(189007,6955,'content_blocks_4_images_0_description',''),(189008,6955,'_content_blocks_4_images_0_description','field_6170d90398010'),(189009,6955,'content_blocks_4_images_1_image',''),(189010,6955,'_content_blocks_4_images_1_image','field_6170d8e99800e'),(189011,6955,'content_blocks_4_images_1_header','Need Image'),(189012,6955,'_content_blocks_4_images_1_header','field_6170d8f49800f'),(189013,6955,'content_blocks_4_images_1_description',''),(189014,6955,'_content_blocks_4_images_1_description','field_6170d90398010'),(189015,6955,'content_blocks_4_images','2'),(189016,6955,'_content_blocks_4_images','field_6170d8df9800d'),(189017,6955,'content_blocks_5_header',''),(189018,6955,'_content_blocks_5_header','field_6170d8ba9800b'),(189019,6955,'content_blocks_5_description','The horsepower between an intensifier style pump and a direct drive pump cannot be directly compared. Each style pump has benefits and drawbacks that must be evaluated based upon each user’s application.\r\n\r\nThe question frequently comes up as to which is better, a direct drive or an intensifier pump. Of course depending upon which manufacturer with which you are talking, you will get different answers. The best way to answer this is to ask the following questions and do your own research:\r\n<ul>\r\n 	<li>What percentage of pumps in use today are intensifier as opposed to direct drive?</li>\r\n 	<li>What percentage of new machines being sold today have intensifier pumps versus direct drive?</li>\r\n 	<li>How many businesses have been created to swap out a direct drive pump with a retrofit kit to change over to an intensifier – basically dispose of the direct drive?</li>\r\n 	<li>How many businesses have been created to swap out an intensifier pump for a direct drive – in other words dispose of an intensifier pump?</li>\r\n 	<li>What are the maintenance costs associated with each style pump for the first 1500 hours, including replacement of consumable and spare parts?</li>\r\n 	<li>How much downtime is involved to replace consumable and spare parts on each style pump?</li>\r\n</ul>'),(189020,6955,'_content_blocks_5_description','field_6170d8cd9800c'),(189021,6955,'content_blocks_5_images',''),(189022,6955,'_content_blocks_5_images','field_6170d8df9800d'),(189023,6955,'content_blocks','19'),(189024,6955,'_content_blocks','field_6170d8ac9800a'),(189025,6955,'menu','37'),(189026,6955,'_menu','field_6170d9e059837'),(189027,6955,'display_left_column','1'),(189028,6955,'_display_left_column','field_613563c4d424b'),(189029,6955,'contact_left_heading',''),(189030,6955,'_contact_left_heading','field_60c249d645c99'),(189031,6955,'contact_left_copy',''),(189032,6955,'_contact_left_copy','field_60c24a0845c9c'),(189033,6955,'display_right_column','1'),(189034,6955,'_display_right_column','field_613563f4d424c'),(189035,6955,'contact_right_heading',''),(189036,6955,'_contact_right_heading','field_60c249e945c9a'),(189037,6955,'contact_right_copy',''),(189038,6955,'_contact_right_copy','field_60c249f845c9b'),(189039,6955,'contact_right_cta',''),(189040,6955,'_contact_right_cta','field_60c24a1945c9d'),(189041,6955,'content_blocks_6_header','Pressure'),(189042,6955,'_content_blocks_6_header','field_6170d8ba9800b'),(189043,6955,'content_blocks_6_description','The pressure of the pump, measured in PSI, will determine cutting speeds for a given orifice size and number of heads. All other things being equal, there is an almost direct correlation between pressure and cutting speed; higher pressure results in higher cutting speeds. From a practical standpoint, increasing pressure also results in higher pump consumable costs, so that must be weighed against the faster cutting speeds.\r\n\r\nThe following graph shows the cutting speeds for ½” (12 mm) stainless steel for a Quality 2 edge finish. The two lines represent two common combinations of orifices and abrasive nozzles. In each case, doubling the pressure from 30,000 psi (2068 bar) to 60,000 psi (4137 bar) results in an increase in linear cutting speed of approximately 2.9 times.\r\n\r\n<b>IMPORTANT:</b> Keep in mind that pump horsepower is not always a direct indication of maximum pressure for the pump. A 200 HP pump may not necessarily have higher pressure than a 100 HP or 50 HP pump.'),(189044,6955,'_content_blocks_6_description','field_6170d8cd9800c'),(189045,6955,'content_blocks_6_images','1'),(189046,6955,'_content_blocks_6_images','field_6170d8df9800d'),(189047,6955,'content_blocks_6_images_0_image','2958'),(189048,6955,'_content_blocks_6_images_0_image','field_6170d8e99800e'),(189049,6955,'content_blocks_6_images_0_header',''),(189050,6955,'_content_blocks_6_images_0_header','field_6170d8f49800f'),(189051,6955,'content_blocks_6_images_0_description',''),(189052,6955,'_content_blocks_6_images_0_description','field_6170d90398010'),(189053,6955,'content_blocks_7_header','Water Output'),(189054,6955,'_content_blocks_7_header','field_6170d8ba9800b'),(189055,6955,'content_blocks_7_description','Water output, or flow rate, is a function of horsepower and pressure. A 50 HP intensifier pump running at 60,000 psi will generally have a maximum output of 1 gallon per minute (gpm). A 100 HP pump running at 60,000 psi will typically put out 2 gpm. This information will help you determine the maximum number of cutting heads that you can use with a pump. Different pump manufacturers will produce slightly different volumes. They may also specify a Maximum Output Pressure and an Operating Output Pressure with different associated water outputs. It is important to verify that the water output specified is what you can expect on a regular production basis (i.e. flow rate based off of Operating Output Pressure).'),(189056,6955,'_content_blocks_7_description','field_6170d8cd9800c'),(189057,6955,'content_blocks_7_images',''),(189058,6955,'_content_blocks_7_images','field_6170d8df9800d'),(189059,6955,'content_blocks_8_header','Orifice selection – The scientific way'),(189060,6955,'_content_blocks_8_header','field_6170d8ba9800b'),(189061,6955,'content_blocks_8_description','The Maximum Continuous Output Pressure and Maximum Output Flow from the “Pump Specifications” in Figure 1 are important in order to understand how many cutting heads you will be able to run with a pump. These numbers can be used in conjunction with the following “Flow Rate Through an Orifice” in Figure 2 to determine the number of cutting heads you can use.\r\n\r\n<b>Example 1</b>: 50 HP Pump, 1 Cutting Head, 60,000 PSI, 1.1 GPM water output\r\n<ol class=\"steps\">\r\n 	<li>If you were looking at the 50 HP pump, from the “Pump Specification” chart you would know that your pump puts out 1.1 gpm at 60,000 psi.</li>\r\n 	<li>You would look down under the “60” column (corresponding to the 60,000 psi pump) in the “Flow Rate” chart until you found a number equal to or less than 1.1. In this case, you would end up at the cell with 1.00.</li>\r\n 	<li>You would then follow that row across to the left to see the maximum size orifice you could use for single-head cutting. In this case, the cell shows that a 0.014” would be the maximum recommended orifice for one head at 60,000 psi.</li>\r\n 	<li>If you were in a tight spot where you only had a 0.015” orifice you might be able to use it by running the pump at 55,000 psi.</li>\r\n</ol>\r\nYou would be at the 1.1 gpm limitation of the pump. If there were any water leaks in your system between the pump and the cutting head, you would likely have a pump “over stroke” situation where the pump would try to cycle too fast attempting to create the required pressure. With modern pumps, there is no harm done if this happens. The pump is simply shut down to protect itself from damage and an error message is displayed for the operator.'),(189062,6955,'_content_blocks_8_description','field_6170d8cd9800c'),(189063,6955,'content_blocks_8_images','1'),(189064,6955,'_content_blocks_8_images','field_6170d8df9800d'),(189065,6955,'content_blocks_8_images_0_image',''),(189066,6955,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(189067,6955,'content_blocks_8_images_0_header','chart needed here'),(189068,6955,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(189069,6955,'content_blocks_8_images_0_description',''),(189070,6955,'_content_blocks_8_images_0_description','field_6170d90398010'),(189071,6955,'content_blocks_9_header','Running Two Cutting Heads'),(189072,6955,'_content_blocks_9_header','field_6170d8ba9800b'),(189073,6955,'content_blocks_9_description','<b>Example 2</b> 50 HP Pump, 2 Cutting Heads, 60,000 PSI, 1.1 GPM water output\r\n\r\nIf you wanted to run 2 cutting heads, then you would take the 1.1 gpm number, divide it by 2 for a maximum of 0.55 gpm per head. Look for the cell under 60 kpsi that has a number smaller than or equal to 0.55. In this case, under the “60” column you would end up in the 0.51 cell, meaning that one 0.010” orifice would put out 0.51 gpm. The maximum number of heads that you could run with the pump at 60 kpsi would be two (1.1 ÷ 2 = 0.55. 0.55 &gt; 0.51 = OK).'),(189074,6955,'_content_blocks_9_description','field_6170d8cd9800c'),(189075,6955,'content_blocks_9_images',''),(189076,6955,'_content_blocks_9_images','field_6170d8df9800d'),(189077,6955,'content_blocks_10_header','Orifice selection – the easy way'),(189078,6955,'_content_blocks_10_header','field_6170d8ba9800b'),(189079,6955,'content_blocks_10_description','Since the pump design engineers have done most of the hard math already, most users need only refer to an “Orifice Selection Chart” similar to the following, which is usually supplied by the pump manufacturer. Here you would quickly see that for the 50 HP pump, you could use either one 0.014” orifice or two 0.010” orifices.'),(189080,6955,'_content_blocks_10_description','field_6170d8cd9800c'),(189081,6955,'content_blocks_10_images_0_image',''),(189082,6955,'_content_blocks_10_images_0_image','field_6170d8e99800e'),(189083,6955,'content_blocks_10_images_0_header','insert table'),(189084,6955,'_content_blocks_10_images_0_header','field_6170d8f49800f'),(189085,6955,'content_blocks_10_images_0_description',''),(189086,6955,'_content_blocks_10_images_0_description','field_6170d90398010'),(189087,6955,'content_blocks_10_images','1'),(189088,6955,'_content_blocks_10_images','field_6170d8df9800d'),(189089,6955,'content_blocks_11_header','General pump selection guidelines'),(189090,6955,'_content_blocks_11_header','field_6170d8ba9800b'),(189091,6955,'content_blocks_11_description','The next step in determining which pump is appropriate for your application is to determine the types of material you will be cutting and how many cutting heads you want to be able to run at one time.\r\n\r\nIf you are cutting parts out of foam, wood, cardboard or other soft materials, then you would be dealing with a pure water application. For pure water applications, a 30 HP pump is usually sufficient. As you can see from the previous Orifice Selection chart, up to three cutting heads could be used with 0.006” orifices.\r\n\r\nIf more cutting heads were needed, then a 50 HP pump could handle up to five cutting heads with 0.006” orifices. For abrasive applications, the 50 HP is the general starting point. With this pump, you can run one head with a 0.014” orifice or two heads with 0.010” orifices. The 0.010” orifice will perform exceptionally well with respect to speed and cut quality on thinner material (1/2” and under).\r\n\r\nThe following graph shows cutting speeds for single head versus dual head cutting in ½” stainless steel. As thickness get beyond 2” (50 mm), the absolute difference in cutting speeds between the nozzle combinations starts to decrease more dramatically.\r\n\r\nCutting with two heads with 0.010” orifices effectively doubles the cutting speed (2 x 5.5 ipm) versus cutting with one head with a 0.010” orifice. Compared to cutting with one head with the 0.014” orifice, cutting with two heads will increase output by about 20 percent. To put this concept into real world terms, it would be like if you started cutting on a job on Monday morning with two cutting heads, then you could get it to your customer by Thursday afternoon. If you cut the job with one head, your customer wouldn’t get the part until Friday afternoon.\r\n\r\nFor someone looking to cut thicker materials on a consistent basis, then we would suggest allocating 50 HP per cutting head. If you selected a 100 HP pump, you could run two heads with 0.014”.\r\n\r\nIf you are cutting very small parts in high volumes, you might want a very large cutting table where you could run four cutting heads and quadruple your production over a single-headed system. In that case you would likely choose the 150 HP pump that can run four heads with 0.013” orifices.'),(189092,6955,'_content_blocks_11_description','field_6170d8cd9800c'),(189093,6955,'content_blocks_11_images_0_image','2960'),(189094,6955,'_content_blocks_11_images_0_image','field_6170d8e99800e'),(189095,6955,'content_blocks_11_images_0_header',''),(189096,6955,'_content_blocks_11_images_0_header','field_6170d8f49800f'),(189097,6955,'content_blocks_11_images_0_description',''),(189098,6955,'_content_blocks_11_images_0_description','field_6170d90398010'),(189099,6955,'content_blocks_11_images','1'),(189100,6955,'_content_blocks_11_images','field_6170d8df9800d'),(189101,6955,'content_blocks_12_header','Abrasive nozzle selection'),(189102,6955,'_content_blocks_12_header','field_6170d8ba9800b'),(189103,6955,'content_blocks_12_description','As a general rule, the diameter of the orifice for the abrasive nozzle should be approximately three times the water nozzle orifice.\r\n\r\nSome people would suggest using a smaller ratio, about 2.5 times. Using a smaller ratio does produce faster cutting speeds. The trade-off is increased nozzle wear and costs. Part tolerance will suffer because of the increased speed of nozzle wear.\r\n\r\nFollowing is a quick reference guide for the most common orifices for abrasive waterjet cutting. Typical abrasive amounts and water flow are also shown for easy reference.'),(189104,6955,'_content_blocks_12_description','field_6170d8cd9800c'),(189105,6955,'content_blocks_12_images_0_image',''),(189106,6955,'_content_blocks_12_images_0_image','field_6170d8e99800e'),(189107,6955,'content_blocks_12_images_0_header','insert chart'),(189108,6955,'_content_blocks_12_images_0_header','field_6170d8f49800f'),(189109,6955,'content_blocks_12_images_0_description',''),(189110,6955,'_content_blocks_12_images_0_description','field_6170d90398010'),(189111,6955,'content_blocks_12_images','1'),(189112,6955,'_content_blocks_12_images','field_6170d8df9800d'),(189113,6955,'content_blocks_13_header','Abrasive amount and cutting speeds'),(189114,6955,'_content_blocks_13_header','field_6170d8ba9800b'),(189115,6955,'content_blocks_13_description','As abrasive is added to the waterjet stream, the abrasive particles are accelerated to near the speed of the waterjet, approximately 2200 miles per hour (almost three times the speed of sound). This speed imparts momentum to the abrasive particles so that they can erode the material. Adding more abrasive gives more energy to the process and erosion occurs faster. Eventually a saturation point occurs where adding more abrasive robs speed and power from the waterjet stream and cutting speeds will start to decrease. Each waterjet manufacturer goes through extensive testing with various orifice and nozzle combinations to find the optimum abrasive amount, balancing cost and cutting speed.\r\n\r\nThe following graph shows what happens to cutting speed for ½” stainless steel as abrasive is added. Speeds are shown for the two most common orifice/abrasive nozzle combinations, 0.010” orifice with a 0.030” abrasive nozzle (orange line) and 0.014” orifice with a 0.040” abrasive nozzle (blue line).\r\n\r\nStarting with an abrasive flow of zero pounds per minute, there would be absolutely no penetration of the material except for maybe a very light etching of the top surface of the material. At this point cutting speed is zero. Cutting speed increases as more and more abrasive is added. For the larger nozzle combination, speed increases until around 1.5 pounds per minute. At this point, cutting speed starts to decrease as too much kinetic energy is removed from the waterjet stream by the abrasive. A similar thing happens with the smaller orifice/nozzle combination, but at slower speeds and lower abrasive amounts.\r\n\r\nThe optimum cost point may be slightly below what looks to be the apex of the speed curve. The “Law of Diminishing Returns” becomes evident. As the maximum speed is approached, each additional unit of abrasive that is added results in an ever smaller increase in speed. In the case of the orange line, increasing the abrasive from 0.7 pounds per minute to 1.0 pounds per minute yields an increase in speed of only 0.2 inches per minute. This 3.6% increase in speed results in a 4.7% increase in cost per inch.'),(189116,6955,'_content_blocks_13_description','field_6170d8cd9800c'),(189117,6955,'content_blocks_13_images_0_image','2830'),(189118,6955,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(189119,6955,'content_blocks_13_images_0_header',''),(189120,6955,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(189121,6955,'content_blocks_13_images_0_description','In Chapter 1, “Cutting Characteristics,” under the section “Creation of the abrasive waterjet stream”, we discussed how the abrasive waterjet stream is created. The cross-section of the cutting head is shown again here.'),(189122,6955,'_content_blocks_13_images_0_description','field_6170d90398010'),(189123,6955,'content_blocks_13_images_1_image','2961'),(189124,6955,'_content_blocks_13_images_1_image','field_6170d8e99800e'),(189125,6955,'content_blocks_13_images_1_header',''),(189126,6955,'_content_blocks_13_images_1_header','field_6170d8f49800f'),(189127,6955,'content_blocks_13_images_1_description',''),(189128,6955,'_content_blocks_13_images_1_description','field_6170d90398010'),(189129,6955,'content_blocks_13_images','2'),(189130,6955,'_content_blocks_13_images','field_6170d8df9800d'),(189131,6955,'content_blocks_14_header','Speed and efficiency of nozzle combinations'),(189132,6955,'_content_blocks_14_header','field_6170d8ba9800b'),(189133,6955,'content_blocks_14_description','We can see in the following graph that larger orifice/abrasive nozzle combinations will cut faster than smaller combinations. With the larger nozzle combination, virtually all of the pump’s power is used, so it will cut faster. The smaller orifice/nozzle cuts slower because less total power from the pump is used.'),(189134,6955,'_content_blocks_14_description','field_6170d8cd9800c'),(189135,6955,'content_blocks_14_images_0_image','2961'),(189136,6955,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(189137,6955,'content_blocks_14_images_0_header',''),(189138,6955,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(189139,6955,'content_blocks_14_images_0_description','Smaller orifice/nozzle combinations are more efficient though in their use of water and abrasive. The available power of the waterjet is concentrated into a smaller area, so more power is directed to the cut.'),(189140,6955,'_content_blocks_14_images_0_description','field_6170d90398010'),(189141,6955,'content_blocks_14_images_1_image','2962'),(189142,6955,'_content_blocks_14_images_1_image','field_6170d8e99800e'),(189143,6955,'content_blocks_14_images_1_header',''),(189144,6955,'_content_blocks_14_images_1_header','field_6170d8f49800f'),(189145,6955,'content_blocks_14_images_1_description','In the picture above, the diameter of the larger waterjet stream on the right is 33% wider and the area of this diameter is 78% greater. This makes the energy density lower than the smaller orifice/nozzle combination. The result is that, as shown earlier and repeated in the graph below, cutting with two 0.010”/0.030” heads is more cost-effective and productive than cutting with one 0.014”/0.040” head in thinner materials (approximately ½” and thinner).'),(189146,6955,'_content_blocks_14_images_1_description','field_6170d90398010'),(189147,6955,'content_blocks_14_images_2_image','2963'),(189148,6955,'_content_blocks_14_images_2_image','field_6170d8e99800e'),(189149,6955,'content_blocks_14_images_2_header',''),(189150,6955,'_content_blocks_14_images_2_header','field_6170d8f49800f'),(189151,6955,'content_blocks_14_images_2_description',''),(189152,6955,'_content_blocks_14_images_2_description','field_6170d90398010'),(189153,6955,'content_blocks_14_images','3'),(189154,6955,'_content_blocks_14_images','field_6170d8df9800d'),(189155,6955,'content_blocks_15_header','Nozzle wear'),(189156,6955,'_content_blocks_15_header','field_6170d8ba9800b'),(189157,6955,'content_blocks_15_description','As the abrasive nozzle wears, the diameter of the abrasive waterjet stream increases. The diameter increases by approximately 0.0001” per hour of cutting. Power per square inch is reduced. Therefore, the feed rate must be reduced in order to maintain the same edge finish, or the quality of the edge will deteriorate.'),(189158,6955,'_content_blocks_15_description','field_6170d8cd9800c'),(189159,6955,'content_blocks_15_images',''),(189160,6955,'_content_blocks_15_images','field_6170d8df9800d'),(189161,6955,'content_blocks_16_header','Cutting speed calculators'),(189162,6955,'_content_blocks_16_header','field_6170d8ba9800b'),(189163,6955,'content_blocks_16_description','Various waterjet feed rate calculators are available online. With these calculators, you can play around with the various parameters to see how cutting speed and cost per inch are affected. Below is an example of one such calculator.\r\n\r\nWith all of these calculators, it is more important to focus on cost per inch (or foot, or meter), rather than cost per hour. Focusing on cost per foot takes into account the diminishing returns discussed in the previous section.\r\n\r\nAnother thing to keep in mind is that these calculators are only showing straight line cutting speeds. Depending upon part geometry, piercing times, machine design and more, actual part cutting times can vary significantly from just taking the total linear inches of cutting in a part and dividing that number by the inches per minute shown in a calculator. The calculators are useful though in at least getting an idea of speeds and costs.'),(189164,6955,'_content_blocks_16_description','field_6170d8cd9800c'),(189165,6955,'content_blocks_16_images_0_image','2965'),(189166,6955,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(189167,6955,'content_blocks_16_images_0_header',''),(189168,6955,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(189169,6955,'content_blocks_16_images_0_description',''),(189170,6955,'_content_blocks_16_images_0_description','field_6170d90398010'),(189171,6955,'content_blocks_16_images','1'),(189172,6955,'_content_blocks_16_images','field_6170d8df9800d'),(189173,6955,'content_blocks_17_header','Machinability Index'),(189174,6955,'_content_blocks_17_header','field_6170d8ba9800b'),(189175,6955,'content_blocks_17_description','The Machinability Index shown in most waterjet feed rate calculators defines the relative cutting rates of different materials. Materials with higher numbers cut proportionately faster than lower numbers. Mild steel has a baseline value of one. Stainless steel at 0.9 would indicate that it cuts about 10% slower than mild steel to achieve similar edge quality and tolerance results.\r\n\r\nIf you know the machinability indexes of two materials, you can estimate fairly easily a good cutting speed of one material from the other. We know that the Machinability Index of stainless steel is 0.9 and below we see that Aluminum’s Machinability Index is 2.9. You know that ½” stainless cuts at 5.5 ipm for the edge quality you want. You want to know the speed for ½” Aluminum. Divide the machinability of Aluminum by the machinability of stainless. 2.9 ÷ 0.9 = 3.2. Multiply the cutting speed for Stainless by 3.2 for the cutting speed in the same thickness of Aluminum. 5.5 ipm x 3.2 = 17.6 ipm. Therefore, 17.6 ipm would be a good place to start for ½” Aluminum.'),(189176,6955,'_content_blocks_17_description','field_6170d8cd9800c'),(189177,6955,'content_blocks_17_images_0_image','2966'),(189178,6955,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(189179,6955,'content_blocks_17_images_0_header',''),(189180,6955,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(189181,6955,'content_blocks_17_images_0_description',''),(189182,6955,'_content_blocks_17_images_0_description','field_6170d90398010'),(189183,6955,'content_blocks_17_images_1_image','2967'),(189184,6955,'_content_blocks_17_images_1_image','field_6170d8e99800e'),(189185,6955,'content_blocks_17_images_1_header',''),(189186,6955,'_content_blocks_17_images_1_header','field_6170d8f49800f'),(189187,6955,'content_blocks_17_images_1_description',''),(189188,6955,'_content_blocks_17_images_1_description','field_6170d90398010'),(189189,6955,'content_blocks_17_images','2'),(189190,6955,'_content_blocks_17_images','field_6170d8df9800d'),(189191,6955,'content_blocks_18_header','Summary'),(189192,6955,'_content_blocks_18_header','field_6170d8ba9800b'),(189193,6955,'content_blocks_18_description','In this chapter we looked at the three critical specifications of a high pressure pump: horsepower, pressure and water output. We reviewed how to figure out what size orifice to use based upon these pump specifications and how many cutting heads are being used. We covered the productivity increases and cost savings of using two smaller orifices versus one large orifice. Additionally, abrasive nozzle diameter selection was discussed in terms of the ratio to the orifice being used. Finally, we looked at waterjet feed rate calculators and how Machinability Indices can be used to extrapolate the cutting speed of one material from a different material.'),(189194,6955,'_content_blocks_18_description','field_6170d8cd9800c'),(189195,6955,'content_blocks_18_images',''),(189196,6955,'_content_blocks_18_images','field_6170d8df9800d'),(189198,6956,'_wp_attached_file','2022/03/Nozzle-and-Orifice-featured-1.jpg'),(189199,6956,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:1920;s:6:\"height\";i:1080;s:4:\"file\";s:41:\"2022/03/Nozzle-and-Orifice-featured-1.jpg\";s:5:\"sizes\";a:5:{s:6:\"medium\";a:4:{s:4:\"file\";s:41:\"Nozzle-and-Orifice-featured-1-300x169.jpg\";s:5:\"width\";i:300;s:6:\"height\";i:169;s:9:\"mime-type\";s:10:\"image/jpeg\";}s:5:\"large\";a:4:{s:4:\"file\";s:42:\"Nozzle-and-Orifice-featured-1-1024x576.jpg\";s:5:\"width\";i:1024;s:6:\"height\";i:576;s:9:\"mime-type\";s:10:\"image/jpeg\";}s:9:\"thumbnail\";a:4:{s:4:\"file\";s:41:\"Nozzle-and-Orifice-featured-1-150x150.jpg\";s:5:\"width\";i:150;s:6:\"height\";i:150;s:9:\"mime-type\";s:10:\"image/jpeg\";}s:12:\"medium_large\";a:4:{s:4:\"file\";s:41:\"Nozzle-and-Orifice-featured-1-768x432.jpg\";s:5:\"width\";i:768;s:6:\"height\";i:432;s:9:\"mime-type\";s:10:\"image/jpeg\";}s:9:\"1536x1536\";a:4:{s:4:\"file\";s:42:\"Nozzle-and-Orifice-featured-1-1536x864.jpg\";s:5:\"width\";i:1536;s:6:\"height\";i:864;s:9:\"mime-type\";s:10:\"image/jpeg\";}}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(189200,6956,'_wp_attachment_image_alt','Nozzle and Orifice featured 1'),(189201,6956,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2848;}}'),(189202,2848,'_thumbnail_id','6956'),(189203,6957,'hero_gallery',''),(189204,6957,'_hero_gallery','field_60c23d554e4a3'),(189205,6957,'hero_banner','6956'),(189206,6957,'_hero_banner','field_6170dbe179470'),(189207,6957,'page_title','Nozzle and Orifice'),(189208,6957,'_page_title','field_6170d88998008'),(189209,6957,'page_description','This section will focus on relationships between speed and edge quality, pump size, water nozzle and abrasive nozzle selection, maximum number of cutting heads and how some of these parameters can change over time.'),(189210,6957,'_page_description','field_6170d89398009'),(189211,6957,'content_blocks_0_header','Desired edge quality'),(189212,6957,'_content_blocks_0_header','field_6170d8ba9800b'),(189213,6957,'content_blocks_0_description','Edge quality is defined with the numbers 1 through 5. Lower numbers indicate rougher edge finish; higher numbers are smoother. For thin materials, the difference in cutting speed for Quality 1 could be as much as 3 times faster than the speed for Quality 5. For thicker materials, Quality 1 could be 6 times faster than Quality 5. For example, 4” thick Aluminum Q5 would be 0.72 ipm (18 mm/min) and Q1 would be 4.2 ipm (107 mm/min), 5.8 times faster.'),(189214,6957,'_content_blocks_0_description','field_6170d8cd9800c'),(189215,6957,'content_blocks_0_images_0_image','2950'),(189216,6957,'_content_blocks_0_images_0_image','field_6170d8e99800e'),(189217,6957,'content_blocks_0_images_0_header','Seperation Cut'),(189218,6957,'_content_blocks_0_images_0_header','field_6170d8f49800f'),(189219,6957,'content_blocks_0_images_0_description',''),(189220,6957,'_content_blocks_0_images_0_description','field_6170d90398010'),(189221,6957,'content_blocks_0_images_1_image','2951'),(189222,6957,'_content_blocks_0_images_1_image','field_6170d8e99800e'),(189223,6957,'content_blocks_0_images_1_header','Through Cut'),(189224,6957,'_content_blocks_0_images_1_header','field_6170d8f49800f'),(189225,6957,'content_blocks_0_images_1_description',''),(189226,6957,'_content_blocks_0_images_1_description','field_6170d90398010'),(189227,6957,'content_blocks_0_images_2_image','2952'),(189228,6957,'_content_blocks_0_images_2_image','field_6170d8e99800e'),(189229,6957,'content_blocks_0_images_2_header','Clean Cut ± 0.010\"'),(189230,6957,'_content_blocks_0_images_2_header','field_6170d8f49800f'),(189231,6957,'content_blocks_0_images_2_description',''),(189232,6957,'_content_blocks_0_images_2_description','field_6170d90398010'),(189233,6957,'content_blocks_0_images_3_image','2953'),(189234,6957,'_content_blocks_0_images_3_image','field_6170d8e99800e'),(189235,6957,'content_blocks_0_images_3_header','Good Finish'),(189236,6957,'_content_blocks_0_images_3_header','field_6170d8f49800f'),(189237,6957,'content_blocks_0_images_3_description',''),(189238,6957,'_content_blocks_0_images_3_description','field_6170d90398010'),(189239,6957,'content_blocks_0_images_4_image','2954'),(189240,6957,'_content_blocks_0_images_4_image','field_6170d8e99800e'),(189241,6957,'content_blocks_0_images_4_header','Excellent Finish ± 0.005\"'),(189242,6957,'_content_blocks_0_images_4_header','field_6170d8f49800f'),(189243,6957,'content_blocks_0_images_4_description',''),(189244,6957,'_content_blocks_0_images_4_description','field_6170d90398010'),(189245,6957,'content_blocks_0_images','5'),(189246,6957,'_content_blocks_0_images','field_6170d8df9800d'),(189247,6957,'content_blocks_1_header','Pump Specification'),(189248,6957,'_content_blocks_1_header','field_6170d8ba9800b'),(189249,6957,'content_blocks_1_description','Every waterjet company will be able to supply a chart similar to the following showing the horsepower, maximum pressure and maximum water output for the pumps offered with their systems.'),(189250,6957,'_content_blocks_1_description','field_6170d8cd9800c'),(189251,6957,'content_blocks_1_images_0_image',''),(189252,6957,'_content_blocks_1_images_0_image','field_6170d8e99800e'),(189253,6957,'content_blocks_1_images_0_header',''),(189254,6957,'_content_blocks_1_images_0_header','field_6170d8f49800f'),(189255,6957,'content_blocks_1_images_0_description',''),(189256,6957,'_content_blocks_1_images_0_description','field_6170d90398010'),(189257,6957,'content_blocks_1_images','1'),(189258,6957,'_content_blocks_1_images','field_6170d8df9800d'),(189259,6957,'content_blocks_2_header','Horsepower, pressure and water output'),(189260,6957,'_content_blocks_2_header','field_6170d8ba9800b'),(189261,6957,'content_blocks_2_description','In order to achieve a required edge quality, cutting speed, tolerance and production requirement in a cost-effective manner, understanding the relationship amongst horsepower, pressure and water output is vital. These factors will determine the maximum size orifice you will be able to use, the maximum number of cutting heads you will be able to run, what speeds you will be able to cut at and the maximum thickness you will be able to cut cost effectively.'),(189262,6957,'_content_blocks_2_description','field_6170d8cd9800c'),(189263,6957,'content_blocks_2_images',''),(189264,6957,'_content_blocks_2_images','field_6170d8df9800d'),(189265,6957,'content_blocks_3_header','Horsepower'),(189266,6957,'_content_blocks_3_header','field_6170d8ba9800b'),(189267,6957,'content_blocks_3_description','Waterjet pumps are specified in either horsepower (HP) or kilowatts (kW) to indicate the size of the electric motor that creates the force to pressurize the water. Engineers will size the hydraulic motor depending upon the water pressure and water output they are trying to achieve.\r\n\r\nThe most common pumps seen on the market today are intensifier style pumps. A simplified diagram of the intensifier concept is shown below. The pumps use hydraulics to apply a certain amount of oil pressure on one side of a piston of a certain diameter. On the water side of the pump, the diameter of the piston is much smaller. The difference in the surface area between the hydraulic side and the water side gives a multiplication factor, or intensification, to the pressure from the oil side. Most intensifier pumps have an intensification ratio of 20 times. This design will be explained in more detail in the “How it Works” chapter.'),(189268,6957,'_content_blocks_3_description','field_6170d8cd9800c'),(189269,6957,'content_blocks_3_images_0_image','2849'),(189270,6957,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(189271,6957,'content_blocks_3_images_0_header',''),(189272,6957,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(189273,6957,'content_blocks_3_images_0_description',''),(189274,6957,'_content_blocks_3_images_0_description','field_6170d90398010'),(189275,6957,'content_blocks_3_images','1'),(189276,6957,'_content_blocks_3_images','field_6170d8df9800d'),(189277,6957,'content_blocks_4_header',''),(189278,6957,'_content_blocks_4_header','field_6170d8ba9800b'),(189279,6957,'content_blocks_4_description','Another style pump sometimes used on waterjets is the direct drive pump. This pump uses an electric motor to turn a crankshaft that moves three or more pistons that create the water pressure, very similar to a car engine. Faster revolutions of the motor create higher pressure and more water volume. The basic concept for the direct drive is shown below.'),(189280,6957,'_content_blocks_4_description','field_6170d8cd9800c'),(189281,6957,'content_blocks_4_images_0_image','2850'),(189282,6957,'_content_blocks_4_images_0_image','field_6170d8e99800e'),(189283,6957,'content_blocks_4_images_0_header',''),(189284,6957,'_content_blocks_4_images_0_header','field_6170d8f49800f'),(189285,6957,'content_blocks_4_images_0_description',''),(189286,6957,'_content_blocks_4_images_0_description','field_6170d90398010'),(189287,6957,'content_blocks_4_images_1_image',''),(189288,6957,'_content_blocks_4_images_1_image','field_6170d8e99800e'),(189289,6957,'content_blocks_4_images_1_header','Need Image'),(189290,6957,'_content_blocks_4_images_1_header','field_6170d8f49800f'),(189291,6957,'content_blocks_4_images_1_description',''),(189292,6957,'_content_blocks_4_images_1_description','field_6170d90398010'),(189293,6957,'content_blocks_4_images','2'),(189294,6957,'_content_blocks_4_images','field_6170d8df9800d'),(189295,6957,'content_blocks_5_header',''),(189296,6957,'_content_blocks_5_header','field_6170d8ba9800b'),(189297,6957,'content_blocks_5_description','The horsepower between an intensifier style pump and a direct drive pump cannot be directly compared. Each style pump has benefits and drawbacks that must be evaluated based upon each user’s application.\r\n\r\nThe question frequently comes up as to which is better, a direct drive or an intensifier pump. Of course depending upon which manufacturer with which you are talking, you will get different answers. The best way to answer this is to ask the following questions and do your own research:\r\n<ul>\r\n 	<li>What percentage of pumps in use today are intensifier as opposed to direct drive?</li>\r\n 	<li>What percentage of new machines being sold today have intensifier pumps versus direct drive?</li>\r\n 	<li>How many businesses have been created to swap out a direct drive pump with a retrofit kit to change over to an intensifier – basically dispose of the direct drive?</li>\r\n 	<li>How many businesses have been created to swap out an intensifier pump for a direct drive – in other words dispose of an intensifier pump?</li>\r\n 	<li>What are the maintenance costs associated with each style pump for the first 1500 hours, including replacement of consumable and spare parts?</li>\r\n 	<li>How much downtime is involved to replace consumable and spare parts on each style pump?</li>\r\n</ul>'),(189298,6957,'_content_blocks_5_description','field_6170d8cd9800c'),(189299,6957,'content_blocks_5_images',''),(189300,6957,'_content_blocks_5_images','field_6170d8df9800d'),(189301,6957,'content_blocks','19'),(189302,6957,'_content_blocks','field_6170d8ac9800a'),(189303,6957,'menu','37'),(189304,6957,'_menu','field_6170d9e059837'),(189305,6957,'display_left_column','1'),(189306,6957,'_display_left_column','field_613563c4d424b'),(189307,6957,'contact_left_heading',''),(189308,6957,'_contact_left_heading','field_60c249d645c99'),(189309,6957,'contact_left_copy',''),(189310,6957,'_contact_left_copy','field_60c24a0845c9c'),(189311,6957,'display_right_column','1'),(189312,6957,'_display_right_column','field_613563f4d424c'),(189313,6957,'contact_right_heading',''),(189314,6957,'_contact_right_heading','field_60c249e945c9a'),(189315,6957,'contact_right_copy',''),(189316,6957,'_contact_right_copy','field_60c249f845c9b'),(189317,6957,'contact_right_cta',''),(189318,6957,'_contact_right_cta','field_60c24a1945c9d'),(189319,6957,'content_blocks_6_header','Pressure'),(189320,6957,'_content_blocks_6_header','field_6170d8ba9800b'),(189321,6957,'content_blocks_6_description','The pressure of the pump, measured in PSI, will determine cutting speeds for a given orifice size and number of heads. All other things being equal, there is an almost direct correlation between pressure and cutting speed; higher pressure results in higher cutting speeds. From a practical standpoint, increasing pressure also results in higher pump consumable costs, so that must be weighed against the faster cutting speeds.\r\n\r\nThe following graph shows the cutting speeds for ½” (12 mm) stainless steel for a Quality 2 edge finish. The two lines represent two common combinations of orifices and abrasive nozzles. In each case, doubling the pressure from 30,000 psi (2068 bar) to 60,000 psi (4137 bar) results in an increase in linear cutting speed of approximately 2.9 times.\r\n\r\n<b>IMPORTANT:</b> Keep in mind that pump horsepower is not always a direct indication of maximum pressure for the pump. A 200 HP pump may not necessarily have higher pressure than a 100 HP or 50 HP pump.'),(189322,6957,'_content_blocks_6_description','field_6170d8cd9800c'),(189323,6957,'content_blocks_6_images','1'),(189324,6957,'_content_blocks_6_images','field_6170d8df9800d'),(189325,6957,'content_blocks_6_images_0_image','2958'),(189326,6957,'_content_blocks_6_images_0_image','field_6170d8e99800e'),(189327,6957,'content_blocks_6_images_0_header',''),(189328,6957,'_content_blocks_6_images_0_header','field_6170d8f49800f'),(189329,6957,'content_blocks_6_images_0_description',''),(189330,6957,'_content_blocks_6_images_0_description','field_6170d90398010'),(189331,6957,'content_blocks_7_header','Water Output'),(189332,6957,'_content_blocks_7_header','field_6170d8ba9800b'),(189333,6957,'content_blocks_7_description','Water output, or flow rate, is a function of horsepower and pressure. A 50 HP intensifier pump running at 60,000 psi will generally have a maximum output of 1 gallon per minute (gpm). A 100 HP pump running at 60,000 psi will typically put out 2 gpm. This information will help you determine the maximum number of cutting heads that you can use with a pump. Different pump manufacturers will produce slightly different volumes. They may also specify a Maximum Output Pressure and an Operating Output Pressure with different associated water outputs. It is important to verify that the water output specified is what you can expect on a regular production basis (i.e. flow rate based off of Operating Output Pressure).'),(189334,6957,'_content_blocks_7_description','field_6170d8cd9800c'),(189335,6957,'content_blocks_7_images',''),(189336,6957,'_content_blocks_7_images','field_6170d8df9800d'),(189337,6957,'content_blocks_8_header','Orifice selection – The scientific way'),(189338,6957,'_content_blocks_8_header','field_6170d8ba9800b'),(189339,6957,'content_blocks_8_description','The Maximum Continuous Output Pressure and Maximum Output Flow from the “Pump Specifications” in Figure 1 are important in order to understand how many cutting heads you will be able to run with a pump. These numbers can be used in conjunction with the following “Flow Rate Through an Orifice” in Figure 2 to determine the number of cutting heads you can use.\r\n\r\n<b>Example 1</b>: 50 HP Pump, 1 Cutting Head, 60,000 PSI, 1.1 GPM water output\r\n<ol class=\"steps\">\r\n 	<li>If you were looking at the 50 HP pump, from the “Pump Specification” chart you would know that your pump puts out 1.1 gpm at 60,000 psi.</li>\r\n 	<li>You would look down under the “60” column (corresponding to the 60,000 psi pump) in the “Flow Rate” chart until you found a number equal to or less than 1.1. In this case, you would end up at the cell with 1.00.</li>\r\n 	<li>You would then follow that row across to the left to see the maximum size orifice you could use for single-head cutting. In this case, the cell shows that a 0.014” would be the maximum recommended orifice for one head at 60,000 psi.</li>\r\n 	<li>If you were in a tight spot where you only had a 0.015” orifice you might be able to use it by running the pump at 55,000 psi.</li>\r\n</ol>\r\nYou would be at the 1.1 gpm limitation of the pump. If there were any water leaks in your system between the pump and the cutting head, you would likely have a pump “over stroke” situation where the pump would try to cycle too fast attempting to create the required pressure. With modern pumps, there is no harm done if this happens. The pump is simply shut down to protect itself from damage and an error message is displayed for the operator.'),(189340,6957,'_content_blocks_8_description','field_6170d8cd9800c'),(189341,6957,'content_blocks_8_images','1'),(189342,6957,'_content_blocks_8_images','field_6170d8df9800d'),(189343,6957,'content_blocks_8_images_0_image',''),(189344,6957,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(189345,6957,'content_blocks_8_images_0_header','chart needed here'),(189346,6957,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(189347,6957,'content_blocks_8_images_0_description',''),(189348,6957,'_content_blocks_8_images_0_description','field_6170d90398010'),(189349,6957,'content_blocks_9_header','Running Two Cutting Heads'),(189350,6957,'_content_blocks_9_header','field_6170d8ba9800b'),(189351,6957,'content_blocks_9_description','<b>Example 2</b> 50 HP Pump, 2 Cutting Heads, 60,000 PSI, 1.1 GPM water output\r\n\r\nIf you wanted to run 2 cutting heads, then you would take the 1.1 gpm number, divide it by 2 for a maximum of 0.55 gpm per head. Look for the cell under 60 kpsi that has a number smaller than or equal to 0.55. In this case, under the “60” column you would end up in the 0.51 cell, meaning that one 0.010” orifice would put out 0.51 gpm. The maximum number of heads that you could run with the pump at 60 kpsi would be two (1.1 ÷ 2 = 0.55. 0.55 &gt; 0.51 = OK).'),(189352,6957,'_content_blocks_9_description','field_6170d8cd9800c'),(189353,6957,'content_blocks_9_images',''),(189354,6957,'_content_blocks_9_images','field_6170d8df9800d'),(189355,6957,'content_blocks_10_header','Orifice selection – the easy way'),(189356,6957,'_content_blocks_10_header','field_6170d8ba9800b'),(189357,6957,'content_blocks_10_description','Since the pump design engineers have done most of the hard math already, most users need only refer to an “Orifice Selection Chart” similar to the following, which is usually supplied by the pump manufacturer. Here you would quickly see that for the 50 HP pump, you could use either one 0.014” orifice or two 0.010” orifices.'),(189358,6957,'_content_blocks_10_description','field_6170d8cd9800c'),(189359,6957,'content_blocks_10_images_0_image',''),(189360,6957,'_content_blocks_10_images_0_image','field_6170d8e99800e'),(189361,6957,'content_blocks_10_images_0_header','insert table'),(189362,6957,'_content_blocks_10_images_0_header','field_6170d8f49800f'),(189363,6957,'content_blocks_10_images_0_description',''),(189364,6957,'_content_blocks_10_images_0_description','field_6170d90398010'),(189365,6957,'content_blocks_10_images','1'),(189366,6957,'_content_blocks_10_images','field_6170d8df9800d'),(189367,6957,'content_blocks_11_header','General pump selection guidelines'),(189368,6957,'_content_blocks_11_header','field_6170d8ba9800b'),(189369,6957,'content_blocks_11_description','The next step in determining which pump is appropriate for your application is to determine the types of material you will be cutting and how many cutting heads you want to be able to run at one time.\r\n\r\nIf you are cutting parts out of foam, wood, cardboard or other soft materials, then you would be dealing with a pure water application. For pure water applications, a 30 HP pump is usually sufficient. As you can see from the previous Orifice Selection chart, up to three cutting heads could be used with 0.006” orifices.\r\n\r\nIf more cutting heads were needed, then a 50 HP pump could handle up to five cutting heads with 0.006” orifices. For abrasive applications, the 50 HP is the general starting point. With this pump, you can run one head with a 0.014” orifice or two heads with 0.010” orifices. The 0.010” orifice will perform exceptionally well with respect to speed and cut quality on thinner material (1/2” and under).\r\n\r\nThe following graph shows cutting speeds for single head versus dual head cutting in ½” stainless steel. As thickness get beyond 2” (50 mm), the absolute difference in cutting speeds between the nozzle combinations starts to decrease more dramatically.\r\n\r\nCutting with two heads with 0.010” orifices effectively doubles the cutting speed (2 x 5.5 ipm) versus cutting with one head with a 0.010” orifice. Compared to cutting with one head with the 0.014” orifice, cutting with two heads will increase output by about 20 percent. To put this concept into real world terms, it would be like if you started cutting on a job on Monday morning with two cutting heads, then you could get it to your customer by Thursday afternoon. If you cut the job with one head, your customer wouldn’t get the part until Friday afternoon.\r\n\r\nFor someone looking to cut thicker materials on a consistent basis, then we would suggest allocating 50 HP per cutting head. If you selected a 100 HP pump, you could run two heads with 0.014”.\r\n\r\nIf you are cutting very small parts in high volumes, you might want a very large cutting table where you could run four cutting heads and quadruple your production over a single-headed system. In that case you would likely choose the 150 HP pump that can run four heads with 0.013” orifices.'),(189370,6957,'_content_blocks_11_description','field_6170d8cd9800c'),(189371,6957,'content_blocks_11_images_0_image','2960'),(189372,6957,'_content_blocks_11_images_0_image','field_6170d8e99800e'),(189373,6957,'content_blocks_11_images_0_header',''),(189374,6957,'_content_blocks_11_images_0_header','field_6170d8f49800f'),(189375,6957,'content_blocks_11_images_0_description',''),(189376,6957,'_content_blocks_11_images_0_description','field_6170d90398010'),(189377,6957,'content_blocks_11_images','1'),(189378,6957,'_content_blocks_11_images','field_6170d8df9800d'),(189379,6957,'content_blocks_12_header','Abrasive nozzle selection'),(189380,6957,'_content_blocks_12_header','field_6170d8ba9800b'),(189381,6957,'content_blocks_12_description','As a general rule, the diameter of the orifice for the abrasive nozzle should be approximately three times the water nozzle orifice.\r\n\r\nSome people would suggest using a smaller ratio, about 2.5 times. Using a smaller ratio does produce faster cutting speeds. The trade-off is increased nozzle wear and costs. Part tolerance will suffer because of the increased speed of nozzle wear.\r\n\r\nFollowing is a quick reference guide for the most common orifices for abrasive waterjet cutting. Typical abrasive amounts and water flow are also shown for easy reference.'),(189382,6957,'_content_blocks_12_description','field_6170d8cd9800c'),(189383,6957,'content_blocks_12_images_0_image',''),(189384,6957,'_content_blocks_12_images_0_image','field_6170d8e99800e'),(189385,6957,'content_blocks_12_images_0_header','insert chart'),(189386,6957,'_content_blocks_12_images_0_header','field_6170d8f49800f'),(189387,6957,'content_blocks_12_images_0_description',''),(189388,6957,'_content_blocks_12_images_0_description','field_6170d90398010'),(189389,6957,'content_blocks_12_images','1'),(189390,6957,'_content_blocks_12_images','field_6170d8df9800d'),(189391,6957,'content_blocks_13_header','Abrasive amount and cutting speeds'),(189392,6957,'_content_blocks_13_header','field_6170d8ba9800b'),(189393,6957,'content_blocks_13_description','As abrasive is added to the waterjet stream, the abrasive particles are accelerated to near the speed of the waterjet, approximately 2200 miles per hour (almost three times the speed of sound). This speed imparts momentum to the abrasive particles so that they can erode the material. Adding more abrasive gives more energy to the process and erosion occurs faster. Eventually a saturation point occurs where adding more abrasive robs speed and power from the waterjet stream and cutting speeds will start to decrease. Each waterjet manufacturer goes through extensive testing with various orifice and nozzle combinations to find the optimum abrasive amount, balancing cost and cutting speed.\r\n\r\nThe following graph shows what happens to cutting speed for ½” stainless steel as abrasive is added. Speeds are shown for the two most common orifice/abrasive nozzle combinations, 0.010” orifice with a 0.030” abrasive nozzle (orange line) and 0.014” orifice with a 0.040” abrasive nozzle (blue line).\r\n\r\nStarting with an abrasive flow of zero pounds per minute, there would be absolutely no penetration of the material except for maybe a very light etching of the top surface of the material. At this point cutting speed is zero. Cutting speed increases as more and more abrasive is added. For the larger nozzle combination, speed increases until around 1.5 pounds per minute. At this point, cutting speed starts to decrease as too much kinetic energy is removed from the waterjet stream by the abrasive. A similar thing happens with the smaller orifice/nozzle combination, but at slower speeds and lower abrasive amounts.\r\n\r\nThe optimum cost point may be slightly below what looks to be the apex of the speed curve. The “Law of Diminishing Returns” becomes evident. As the maximum speed is approached, each additional unit of abrasive that is added results in an ever smaller increase in speed. In the case of the orange line, increasing the abrasive from 0.7 pounds per minute to 1.0 pounds per minute yields an increase in speed of only 0.2 inches per minute. This 3.6% increase in speed results in a 4.7% increase in cost per inch.'),(189394,6957,'_content_blocks_13_description','field_6170d8cd9800c'),(189395,6957,'content_blocks_13_images_0_image','2830'),(189396,6957,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(189397,6957,'content_blocks_13_images_0_header',''),(189398,6957,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(189399,6957,'content_blocks_13_images_0_description','In Chapter 1, “Cutting Characteristics,” under the section “Creation of the abrasive waterjet stream”, we discussed how the abrasive waterjet stream is created. The cross-section of the cutting head is shown again here.'),(189400,6957,'_content_blocks_13_images_0_description','field_6170d90398010'),(189401,6957,'content_blocks_13_images_1_image','2961'),(189402,6957,'_content_blocks_13_images_1_image','field_6170d8e99800e'),(189403,6957,'content_blocks_13_images_1_header',''),(189404,6957,'_content_blocks_13_images_1_header','field_6170d8f49800f'),(189405,6957,'content_blocks_13_images_1_description',''),(189406,6957,'_content_blocks_13_images_1_description','field_6170d90398010'),(189407,6957,'content_blocks_13_images','2'),(189408,6957,'_content_blocks_13_images','field_6170d8df9800d'),(189409,6957,'content_blocks_14_header','Speed and efficiency of nozzle combinations'),(189410,6957,'_content_blocks_14_header','field_6170d8ba9800b'),(189411,6957,'content_blocks_14_description','We can see in the following graph that larger orifice/abrasive nozzle combinations will cut faster than smaller combinations. With the larger nozzle combination, virtually all of the pump’s power is used, so it will cut faster. The smaller orifice/nozzle cuts slower because less total power from the pump is used.'),(189412,6957,'_content_blocks_14_description','field_6170d8cd9800c'),(189413,6957,'content_blocks_14_images_0_image','2961'),(189414,6957,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(189415,6957,'content_blocks_14_images_0_header',''),(189416,6957,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(189417,6957,'content_blocks_14_images_0_description','Smaller orifice/nozzle combinations are more efficient though in their use of water and abrasive. The available power of the waterjet is concentrated into a smaller area, so more power is directed to the cut.'),(189418,6957,'_content_blocks_14_images_0_description','field_6170d90398010'),(189419,6957,'content_blocks_14_images_1_image','2962'),(189420,6957,'_content_blocks_14_images_1_image','field_6170d8e99800e'),(189421,6957,'content_blocks_14_images_1_header',''),(189422,6957,'_content_blocks_14_images_1_header','field_6170d8f49800f'),(189423,6957,'content_blocks_14_images_1_description','In the picture above, the diameter of the larger waterjet stream on the right is 33% wider and the area of this diameter is 78% greater. This makes the energy density lower than the smaller orifice/nozzle combination. The result is that, as shown earlier and repeated in the graph below, cutting with two 0.010”/0.030” heads is more cost-effective and productive than cutting with one 0.014”/0.040” head in thinner materials (approximately ½” and thinner).'),(189424,6957,'_content_blocks_14_images_1_description','field_6170d90398010'),(189425,6957,'content_blocks_14_images_2_image','2963'),(189426,6957,'_content_blocks_14_images_2_image','field_6170d8e99800e'),(189427,6957,'content_blocks_14_images_2_header',''),(189428,6957,'_content_blocks_14_images_2_header','field_6170d8f49800f'),(189429,6957,'content_blocks_14_images_2_description',''),(189430,6957,'_content_blocks_14_images_2_description','field_6170d90398010'),(189431,6957,'content_blocks_14_images','3'),(189432,6957,'_content_blocks_14_images','field_6170d8df9800d'),(189433,6957,'content_blocks_15_header','Nozzle wear'),(189434,6957,'_content_blocks_15_header','field_6170d8ba9800b'),(189435,6957,'content_blocks_15_description','As the abrasive nozzle wears, the diameter of the abrasive waterjet stream increases. The diameter increases by approximately 0.0001” per hour of cutting. Power per square inch is reduced. Therefore, the feed rate must be reduced in order to maintain the same edge finish, or the quality of the edge will deteriorate.'),(189436,6957,'_content_blocks_15_description','field_6170d8cd9800c'),(189437,6957,'content_blocks_15_images',''),(189438,6957,'_content_blocks_15_images','field_6170d8df9800d'),(189439,6957,'content_blocks_16_header','Cutting speed calculators'),(189440,6957,'_content_blocks_16_header','field_6170d8ba9800b'),(189441,6957,'content_blocks_16_description','Various waterjet feed rate calculators are available online. With these calculators, you can play around with the various parameters to see how cutting speed and cost per inch are affected. Below is an example of one such calculator.\r\n\r\nWith all of these calculators, it is more important to focus on cost per inch (or foot, or meter), rather than cost per hour. Focusing on cost per foot takes into account the diminishing returns discussed in the previous section.\r\n\r\nAnother thing to keep in mind is that these calculators are only showing straight line cutting speeds. Depending upon part geometry, piercing times, machine design and more, actual part cutting times can vary significantly from just taking the total linear inches of cutting in a part and dividing that number by the inches per minute shown in a calculator. The calculators are useful though in at least getting an idea of speeds and costs.'),(189442,6957,'_content_blocks_16_description','field_6170d8cd9800c'),(189443,6957,'content_blocks_16_images_0_image','2965'),(189444,6957,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(189445,6957,'content_blocks_16_images_0_header',''),(189446,6957,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(189447,6957,'content_blocks_16_images_0_description',''),(189448,6957,'_content_blocks_16_images_0_description','field_6170d90398010'),(189449,6957,'content_blocks_16_images','1'),(189450,6957,'_content_blocks_16_images','field_6170d8df9800d'),(189451,6957,'content_blocks_17_header','Machinability Index'),(189452,6957,'_content_blocks_17_header','field_6170d8ba9800b'),(189453,6957,'content_blocks_17_description','The Machinability Index shown in most waterjet feed rate calculators defines the relative cutting rates of different materials. Materials with higher numbers cut proportionately faster than lower numbers. Mild steel has a baseline value of one. Stainless steel at 0.9 would indicate that it cuts about 10% slower than mild steel to achieve similar edge quality and tolerance results.\r\n\r\nIf you know the machinability indexes of two materials, you can estimate fairly easily a good cutting speed of one material from the other. We know that the Machinability Index of stainless steel is 0.9 and below we see that Aluminum’s Machinability Index is 2.9. You know that ½” stainless cuts at 5.5 ipm for the edge quality you want. You want to know the speed for ½” Aluminum. Divide the machinability of Aluminum by the machinability of stainless. 2.9 ÷ 0.9 = 3.2. Multiply the cutting speed for Stainless by 3.2 for the cutting speed in the same thickness of Aluminum. 5.5 ipm x 3.2 = 17.6 ipm. Therefore, 17.6 ipm would be a good place to start for ½” Aluminum.'),(189454,6957,'_content_blocks_17_description','field_6170d8cd9800c'),(189455,6957,'content_blocks_17_images_0_image','2966'),(189456,6957,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(189457,6957,'content_blocks_17_images_0_header',''),(189458,6957,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(189459,6957,'content_blocks_17_images_0_description',''),(189460,6957,'_content_blocks_17_images_0_description','field_6170d90398010'),(189461,6957,'content_blocks_17_images_1_image','2967'),(189462,6957,'_content_blocks_17_images_1_image','field_6170d8e99800e'),(189463,6957,'content_blocks_17_images_1_header',''),(189464,6957,'_content_blocks_17_images_1_header','field_6170d8f49800f'),(189465,6957,'content_blocks_17_images_1_description',''),(189466,6957,'_content_blocks_17_images_1_description','field_6170d90398010'),(189467,6957,'content_blocks_17_images','2'),(189468,6957,'_content_blocks_17_images','field_6170d8df9800d'),(189469,6957,'content_blocks_18_header','Summary'),(189470,6957,'_content_blocks_18_header','field_6170d8ba9800b'),(189471,6957,'content_blocks_18_description','In this chapter we looked at the three critical specifications of a high pressure pump: horsepower, pressure and water output. We reviewed how to figure out what size orifice to use based upon these pump specifications and how many cutting heads are being used. We covered the productivity increases and cost savings of using two smaller orifices versus one large orifice. Additionally, abrasive nozzle diameter selection was discussed in terms of the ratio to the orifice being used. Finally, we looked at waterjet feed rate calculators and how Machinability Indices can be used to extrapolate the cutting speed of one material from a different material.'),(189472,6957,'_content_blocks_18_description','field_6170d8cd9800c'),(189473,6957,'content_blocks_18_images',''),(189474,6957,'_content_blocks_18_images','field_6170d8df9800d'),(189476,2970,'hefo_before','0'),(189477,2970,'hefo_after','0'),(189478,6958,'hero_gallery',''),(189479,6958,'_hero_gallery','field_60c23d554e4a3'),(189480,6958,'hero_banner','6934'),(189481,6958,'_hero_banner','field_6170dbe179470'),(189482,6958,'page_title','Pumps'),(189483,6958,'_page_title','field_6170d88998008'),(189484,6958,'page_description','This chapter will discuss the pressurization of water in more detail, the two main pump designs that are used to do this, parts of the intensifier pump and troubleshooting of leaks in the intensifier pump. Transport and metering of abrasive will also be covered.'),(189485,6958,'_page_description','field_6170d89398009'),(189486,6958,'content_blocks_0_header','High pressure waterjet cutting'),(189487,6958,'_content_blocks_0_header','field_6170d8ba9800b'),(189488,6958,'content_blocks_0_description','Water is pressurized to very high pressures, in excess of 50,000 psi. This pressurization is accomplished with the use of pumps of various designs, discussed next in this chapter.\r\n\r\nThe high pressure water is transported through a series of stainless steel tubes to a cutting head. Depending upon the material being cut, the cutting head can be either a \"pure water cutting head\" or an \"abrasive cutting head.\"\r\n\r\nIn the cutting head, the high pressure water is forced through a small diameter orifice. The diameter of this orifice is anywhere from 0.004\" to 0.020\". This step converts the pressure of the waterjet stream into speed. We go from potential energy to kinetic energy. Coming out of the orifice, the waterjet stream is moving at 2200 mph or faster. Higher pressure results in higher speed. Smaller diameter orifices yield a faster waterjet stream, but also a stream with less kinetic energy since there is not as much water available to accelerate abrasive grains to full speed.\r\n\r\nIn a pure water cutting head, the water immediately exits the cutting head after passing through the orifice. The speed and power of the waterjet stream is enough to cut soft or thin materials like foam, rubber, soft wood, plastics, carpet, food, car headliners, circuit boards and more.\r\n\r\nIn an abrasive cutting head, a very hard abrasive, typically garnet, is fed into the waterjet stream. The abrasive particles are accelerated to near the speed of the waterjet stream. This gives the abrasive particles much power. The abrasive waterjet stream now travels down through an abrasive nozzle, or mixing tube, approximately 3 inches long with an inner diameter of between .030\" and 0.050\". The mixture of water and abrasive exits the abrasive nozzle and will cut hard materials like metals, stone, acrylic, ceramic, composites, phenolics and porcelain.\r\n\r\nA CNC control will move the cutting head in up to 6 axes of motion to cut the targeted work piece.'),(189489,6958,'_content_blocks_0_description','field_6170d8cd9800c'),(189490,6958,'content_blocks_0_images',''),(189491,6958,'_content_blocks_0_images','field_6170d8df9800d'),(189492,6958,'content_blocks_1_header','Types of pumps'),(189493,6958,'_content_blocks_1_header','field_6170d8ba9800b'),(189494,6958,'content_blocks_1_description',''),(189495,6958,'_content_blocks_1_description','field_6170d8cd9800c'),(189496,6958,'content_blocks_1_images',''),(189497,6958,'_content_blocks_1_images','field_6170d8df9800d'),(189498,6958,'content_blocks_2_header','Intensifier'),(189499,6958,'_content_blocks_2_header','field_6170d8ba9800b'),(189500,6958,'content_blocks_2_description','Intensifier pumps are called intensifiers because they use the concept of pressure intensification or amplification to generate the desired water pressure.\r\n\r\nIf you apply pressure to one side of a cylinder and the other side of the cylinder is the same surface area, the pressure on the other side will be the same. If the surface area of the smaller side is half, then the pressure on that side will be doubled. Generally with intensifier pumps there is a 20 times difference between the large surface area (where the oil pressure is applied) and the small surface area (where the water pressure is generated). The following picture shows this concept.\r\n\r\nUltimately, there must be a restriction in the flow of water in order for the pressure to be generated. This restriction is generated by the orifice in the cutting head. Pressure is maintained until the orifice diameter exceeds the limits for water output of the pump.\r\n\r\nFor very small diameter orifices, in order to maintain pressure, the pump only needs to cycle very slowly to maintain pressure. As the orifice gets larger, the pump must work faster to maintain pressure and water flow. If the orifice gets too large, the pump tries to cycle too fast for the design specification. An \"over stroke\" situation is sensed by the control and the pump is stopped with an error message.\r\n\r\nIf there are leaks in the water circuit between the pump and the cutting head, this can also result in a pump \"over stroke\" situation. The leaks effectively rob water available to go to the cutting head. The same as putting in too large of an orifice, the pump runs faster to maintain pressure until it reaches its limit.\r\n\r\nTypically, intensifiers stroke at around 50 - 60 strokes per minute when working at full capacity.'),(189501,6958,'_content_blocks_2_description','field_6170d8cd9800c'),(189502,6958,'content_blocks_2_images_0_image','2971'),(189503,6958,'_content_blocks_2_images_0_image','field_6170d8e99800e'),(189504,6958,'content_blocks_2_images_0_header',''),(189505,6958,'_content_blocks_2_images_0_header','field_6170d8f49800f'),(189506,6958,'content_blocks_2_images_0_description',''),(189507,6958,'_content_blocks_2_images_0_description','field_6170d90398010'),(189508,6958,'content_blocks_2_images','1'),(189509,6958,'_content_blocks_2_images','field_6170d8df9800d'),(189510,6958,'content_blocks_3_header','The pressurization process'),(189511,6958,'_content_blocks_3_header','field_6170d8ba9800b'),(189512,6958,'content_blocks_3_description','<ol class=\"steps\">\r\n 	<li>Oil is forced into the right half of the hydraulic cylinder.</li>\r\n 	<li>The piston-plunger assembly moves to the left. Oil is displaced out of the left half of the hydraulic cylinder and the water in the left high pressure cylinder is pressurized.</li>\r\n 	<li>The plunger moves to the left.</li>\r\n 	<li>Once pressure has begun to build, the high pressure water is forced out of the intensifier through the center of the check valve.</li>\r\n 	<li>While the piston-plunger assembly is moving to the left, it is also allowing fresh water to flow into the right high pressure cylinder through the inlet holes of the check valve.</li>\r\n 	<li>When the plunger-piston assembly has reached the end of its stroke to the left, the right high pressure cylinder is now full of water.</li>\r\n 	<li>The directional control valve receives a signal via a proximity sensor near the piston to reverse the flow of hydraulic oil. Oil is now forced into the left half of the hydraulic cylinder and the piston moves to the right.</li>\r\n 	<li>Oil is displaced out of the right half of the hydraulic cylinder while the water in the right high pressure cylinder is pressurized by the right plunger.</li>\r\n</ol>'),(189513,6958,'_content_blocks_3_description','field_6170d8cd9800c'),(189514,6958,'content_blocks_3_images_0_image','2972'),(189515,6958,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(189516,6958,'content_blocks_3_images_0_header',''),(189517,6958,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(189518,6958,'content_blocks_3_images_0_description',''),(189519,6958,'_content_blocks_3_images_0_description','field_6170d90398010'),(189520,6958,'content_blocks_3_images_1_image','2973'),(189521,6958,'_content_blocks_3_images_1_image','field_6170d8e99800e'),(189522,6958,'content_blocks_3_images_1_header',''),(189523,6958,'_content_blocks_3_images_1_header','field_6170d8f49800f'),(189524,6958,'content_blocks_3_images_1_description',''),(189525,6958,'_content_blocks_3_images_1_description','field_6170d90398010'),(189526,6958,'content_blocks_3_images','2'),(189527,6958,'_content_blocks_3_images','field_6170d8df9800d'),(189528,6958,'content_blocks','24'),(189529,6958,'_content_blocks','field_6170d8ac9800a'),(189530,6958,'menu','37'),(189531,6958,'_menu','field_6170d9e059837'),(189532,6958,'display_left_column','1'),(189533,6958,'_display_left_column','field_613563c4d424b'),(189534,6958,'contact_left_heading',''),(189535,6958,'_contact_left_heading','field_60c249d645c99'),(189536,6958,'contact_left_copy',''),(189537,6958,'_contact_left_copy','field_60c24a0845c9c'),(189538,6958,'display_right_column','1'),(189539,6958,'_display_right_column','field_613563f4d424c'),(189540,6958,'contact_right_heading',''),(189541,6958,'_contact_right_heading','field_60c249e945c9a'),(189542,6958,'contact_right_copy',''),(189543,6958,'_contact_right_copy','field_60c249f845c9b'),(189544,6958,'contact_right_cta',''),(189545,6958,'_contact_right_cta','field_60c24a1945c9d'),(189546,6958,'content_blocks_4_header','Direct Drive'),(189547,6958,'_content_blocks_4_header','field_6170d8ba9800b'),(189548,6958,'content_blocks_4_description','A direct drive pump works like a car’s engine. A motor turns a crankshaft attached to 3 or more offset pistons. As the crankshaft turns, the pistons reciprocate in their respective cylinders, creating pressure in the water. Pressure and flow rate are determined by how fast the motor turns the crankshaft.\r\n\r\nDirect drive pumps cycle much faster than intensifiers, on the order of 1750 revolutions per minute. Direct drive pumps generally are found in lower pressure applications (i.e. 55,000 pounds per square inch and under). Maintenance on the direct drive pump tends to take longer than an intensifier pump. Direct drive pumps can only run more than one cutting head only if all cutting heads are cutting the same part at the same time. With an intensifier pump, you could have cutting heads on multiple machines, cutting different parts, cycling the various cutting heads on and off in any sequence. The intensifier pump will need to only vary its stroke rate accordingly to maintain flow and pressure.'),(189549,6958,'_content_blocks_4_description','field_6170d8cd9800c'),(189550,6958,'content_blocks_4_images_0_image','2976'),(189551,6958,'_content_blocks_4_images_0_image','field_6170d8e99800e'),(189552,6958,'content_blocks_4_images_0_header',''),(189553,6958,'_content_blocks_4_images_0_header','field_6170d8f49800f'),(189554,6958,'content_blocks_4_images_0_description',''),(189555,6958,'_content_blocks_4_images_0_description','field_6170d90398010'),(189556,6958,'content_blocks_4_images_1_image','2977'),(189557,6958,'_content_blocks_4_images_1_image','field_6170d8e99800e'),(189558,6958,'content_blocks_4_images_1_header',''),(189559,6958,'_content_blocks_4_images_1_header','field_6170d8f49800f'),(189560,6958,'content_blocks_4_images_1_description',''),(189561,6958,'_content_blocks_4_images_1_description','field_6170d90398010'),(189562,6958,'content_blocks_4_images','2'),(189563,6958,'_content_blocks_4_images','field_6170d8df9800d'),(189564,6958,'content_blocks_5_header','Generating High Pressure Water: Direct Drive Pumps'),(189565,6958,'_content_blocks_5_header','field_6170d8ba9800b'),(189566,6958,'content_blocks_5_description','<ul class=\"steps\">\r\n 	<li>3 plungers directly coupled to a crank shaft</li>\r\n 	<li>Pressure and flow rate are determined by how fast the motor turns the crankshaft</li>\r\n 	<li>Crank shaft cycles at up to 1750 rpm</li>\r\n 	<li>Minimal pressure spikes (no attenuator needed)</li>\r\n 	<li>Generally found in lower pressure applications</li>\r\n 	<li>Cutting water is always running while the pump is on. The water either goes through the cutting head, or, when not cutting, through the dump valve into the waterjet tank.</li>\r\n</ul>\r\n<h3>Disadvantages</h3>\r\n<ul class=\"steps\">\r\n 	<li>Complex - Many moving parts</li>\r\n 	<li>Time consuming to maintain</li>\r\n 	<li>Able to support additional cutting heads ONLY when the heads are cutting the same part (Pump is always pressurized)</li>\r\n 	<li>Expensive</li>\r\n</ul>\r\n<h3>Advantages</h3>\r\n<ul class=\"steps\">\r\n 	<li>High efficiency</li>\r\n 	<li>Low pressure fluctuations</li>\r\n 	<li>No attenuator</li>\r\n</ul>'),(189567,6958,'_content_blocks_5_description','field_6170d8cd9800c'),(189568,6958,'content_blocks_5_images_0_image','2979'),(189569,6958,'_content_blocks_5_images_0_image','field_6170d8e99800e'),(189570,6958,'content_blocks_5_images_0_header',''),(189571,6958,'_content_blocks_5_images_0_header','field_6170d8f49800f'),(189572,6958,'content_blocks_5_images_0_description',''),(189573,6958,'_content_blocks_5_images_0_description','field_6170d90398010'),(189574,6958,'content_blocks_5_images_1_image','2980'),(189575,6958,'_content_blocks_5_images_1_image','field_6170d8e99800e'),(189576,6958,'content_blocks_5_images_1_header',''),(189577,6958,'_content_blocks_5_images_1_header','field_6170d8f49800f'),(189578,6958,'content_blocks_5_images_1_description',''),(189579,6958,'_content_blocks_5_images_1_description','field_6170d90398010'),(189580,6958,'content_blocks_5_images','2'),(189581,6958,'_content_blocks_5_images','field_6170d8df9800d'),(189582,6958,'content_blocks_6_header','Parts of the intensifier pump'),(189583,6958,'_content_blocks_6_header','field_6170d8ba9800b'),(189584,6958,'content_blocks_6_description',''),(189585,6958,'_content_blocks_6_description','field_6170d8cd9800c'),(189586,6958,'content_blocks_6_images',''),(189587,6958,'_content_blocks_6_images','field_6170d8df9800d'),(189588,6958,'content_blocks_7_header','1. Electric motor and hydraulic pump'),(189589,6958,'_content_blocks_7_header','field_6170d8ba9800b'),(189590,6958,'content_blocks_7_description','The electric motor and hydraulic pump (number 1 in picture above) create the oil pressure needed for the oil side of the intensifier. This assembly is normally in the lower portion of the pump cabinet. The electric motor and pump are rated in HP (or kW for metric). Typical pump sizes are 30 HP, 50 HP, 75 HP, 100 HP and 150 HP As discussed in the previous chapter, each pump will have an associated water output volume (gallons per minute) and pressure (psi).\r\n\r\nAgain it is important to remember that HP is not necessarily an indication of pressure. A 150 HP pump doesn’t necessarily create more pressure than a 50 HP pump. Horsepower is more directly related to water output, since more HP will be needed to create enough power to move the piston/plunger assembly in the intensifier at the required stroke rate.'),(189591,6958,'_content_blocks_7_description','field_6170d8cd9800c'),(189592,6958,'content_blocks_7_images_0_image','2981'),(189593,6958,'_content_blocks_7_images_0_image','field_6170d8e99800e'),(189594,6958,'content_blocks_7_images_0_header',''),(189595,6958,'_content_blocks_7_images_0_header','field_6170d8f49800f'),(189596,6958,'content_blocks_7_images_0_description',''),(189597,6958,'_content_blocks_7_images_0_description','field_6170d90398010'),(189598,6958,'content_blocks_7_images','1'),(189599,6958,'_content_blocks_7_images','field_6170d8df9800d'),(189600,6958,'content_blocks_8_header','2. Directional control valves'),(189601,6958,'_content_blocks_8_header','field_6170d8ba9800b'),(189602,6958,'content_blocks_8_description','The directional control valve (2 in Figures 2 and 3) controls the direction of flow of the hydraulic oil to and from the intensifier.'),(189603,6958,'_content_blocks_8_description','field_6170d8cd9800c'),(189604,6958,'content_blocks_8_images_0_image','2982'),(189605,6958,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(189606,6958,'content_blocks_8_images_0_header',''),(189607,6958,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(189608,6958,'content_blocks_8_images_0_description',''),(189609,6958,'_content_blocks_8_images_0_description','field_6170d90398010'),(189610,6958,'content_blocks_8_images','1'),(189611,6958,'_content_blocks_8_images','field_6170d8df9800d'),(189612,6958,'content_blocks_9_header','3. Intensifier'),(189613,6958,'_content_blocks_9_header','field_6170d8ba9800b'),(189614,6958,'content_blocks_9_description','The intensifier proper (3 in Figures 4 and 2) consists of the hydraulic cylinder (4), high pressure cylinders (7), and check valves (8) and end caps (9). Not visible from the outside are the piston and plunger.'),(189615,6958,'_content_blocks_9_description','field_6170d8cd9800c'),(189616,6958,'content_blocks_9_images_0_image','2984'),(189617,6958,'_content_blocks_9_images_0_image','field_6170d8e99800e'),(189618,6958,'content_blocks_9_images_0_header',''),(189619,6958,'_content_blocks_9_images_0_header','field_6170d8f49800f'),(189620,6958,'content_blocks_9_images_0_description',''),(189621,6958,'_content_blocks_9_images_0_description','field_6170d90398010'),(189622,6958,'content_blocks_9_images','1'),(189623,6958,'_content_blocks_9_images','field_6170d8df9800d'),(189624,6958,'content_blocks_10_header','4. Hydraulic cylinder'),(189625,6958,'_content_blocks_10_header','field_6170d8ba9800b'),(189626,6958,'content_blocks_10_description','The hydraulic cylinder (4 in Figures 2 and 5) houses the piston and is the area where the hydraulic oil does its work. The directional control valves control the flow of oil into and out of each side of the hydraulic cylinder.\r\n\r\nAt each end of the hydraulic cylinder is an end plate that is used to connect the hydraulic cylinder to the high pressure cylinder. The two end plates for the hydraulic cylinder are connected and pulled tightly in place with 4 tie rods and bolts.'),(189627,6958,'_content_blocks_10_description','field_6170d8cd9800c'),(189628,6958,'content_blocks_10_images_0_image','2985'),(189629,6958,'_content_blocks_10_images_0_image','field_6170d8e99800e'),(189630,6958,'content_blocks_10_images_0_header',''),(189631,6958,'_content_blocks_10_images_0_header','field_6170d8f49800f'),(189632,6958,'content_blocks_10_images_0_description',''),(189633,6958,'_content_blocks_10_images_0_description','field_6170d90398010'),(189634,6958,'content_blocks_10_images','1'),(189635,6958,'_content_blocks_10_images','field_6170d8df9800d'),(189636,6958,'content_blocks_11_header','5. Piston'),(189637,6958,'_content_blocks_11_header','field_6170d8ba9800b'),(189638,6958,'content_blocks_11_description','The piston (number 5 in Figures 2 and 6) is the larger diameter cylindrical part located within the hydraulic cylinder (4 in Figures 2 and 5). The piston effectively splits the hydraulic cylinder into a left side and a right side. Oil cannot pass from one side to the other past the piston. It must exit and enter the hydraulic cylinder through the hoses attached to the directional control valve. The hydraulic oil pressure is exerted onto either side of the piston in an alternating fashion so that a back-and-forth movement of the piston and plunger assembly is generated.'),(189639,6958,'_content_blocks_11_description','field_6170d8cd9800c'),(189640,6958,'content_blocks_11_images_0_image','2986'),(189641,6958,'_content_blocks_11_images_0_image','field_6170d8e99800e'),(189642,6958,'content_blocks_11_images_0_header',''),(189643,6958,'_content_blocks_11_images_0_header','field_6170d8f49800f'),(189644,6958,'content_blocks_11_images_0_description','Figure 6 - Piston (5) and plunger (6) assembly'),(189645,6958,'_content_blocks_11_images_0_description','field_6170d90398010'),(189646,6958,'content_blocks_11_images','1'),(189647,6958,'_content_blocks_11_images','field_6170d8df9800d'),(189648,6958,'content_blocks_12_header','6. Plunger'),(189649,6958,'_content_blocks_12_header','field_6170d8ba9800b'),(189650,6958,'content_blocks_12_description','The plungers (6 in Figure 7) are the two smaller diameter shafts that are connected to each side of the piston. The attachment point is inside of the hydraulic cylinder. The other ends of the plungers extend into the left and right high pressure cylinders. Seals are placed around the plunger shaft to keep oil from seeping into the water side of the pump, and vice versa. The plungers are made out of either stainless steel, or, more recently, ceramic. Ceramic is used because of its ability to handle heat and high pressure with little thermal expansion.'),(189651,6958,'_content_blocks_12_description','field_6170d8cd9800c'),(189652,6958,'content_blocks_12_images_0_image','2987'),(189653,6958,'_content_blocks_12_images_0_image','field_6170d8e99800e'),(189654,6958,'content_blocks_12_images_0_header',''),(189655,6958,'_content_blocks_12_images_0_header','field_6170d8f49800f'),(189656,6958,'content_blocks_12_images_0_description','Figure 7 - Ceramic plunger'),(189657,6958,'_content_blocks_12_images_0_description','field_6170d90398010'),(189658,6958,'content_blocks_12_images','1'),(189659,6958,'_content_blocks_12_images','field_6170d8df9800d'),(189660,6958,'content_blocks_13_header','7. High pressure cylinder'),(189661,6958,'_content_blocks_13_header','field_6170d8ba9800b'),(189662,6958,'content_blocks_13_description','The two high pressure cylinders (7 in Figures 8 and 2) are where the water is pressurized. They are usually referred to as \"left hand side\" and \"right hand side.\" The high pressure cylinders are machined out of very thick stainless steel and treated in order to withstand the extreme pressures they are put under on a continual, cyclical basis.'),(189663,6958,'_content_blocks_13_description','field_6170d8cd9800c'),(189664,6958,'content_blocks_13_images_0_image','2984'),(189665,6958,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(189666,6958,'content_blocks_13_images_0_header',''),(189667,6958,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(189668,6958,'content_blocks_13_images_0_description',''),(189669,6958,'_content_blocks_13_images_0_description','field_6170d90398010'),(189670,6958,'content_blocks_13_images','1'),(189671,6958,'_content_blocks_13_images','field_6170d8df9800d'),(189672,6958,'content_blocks_14_header','8. Check valve'),(189673,6958,'_content_blocks_14_header','field_6170d8ba9800b'),(189674,6958,'content_blocks_14_description','There is one check valve (number 8 in Figures 10 and 8) at the end of each high pressure cylinder at the end opposite from the hydraulic cylinder. The check valve allows fresh water to enter the high pressure cylinder and high pressure water to exit the intensifier. The check valve is designed to only let water flow in one direction. Fresh water comes in though channels machined in the sides and exits through one or more holes in the face of the valve. Various seals, poppets and springs are used to maintain this water flow. Over several hundred hours these components will wear, allowing pressurized water to flow out the water inlet path, or allowing pressurized water to seep back into the high pressure cylinder. The symptoms and diagnosis of these various situations will be discussed later in the \"Maintenance\" chapter.'),(189675,6958,'_content_blocks_14_description','field_6170d8cd9800c'),(189676,6958,'content_blocks_14_images_0_image','2988'),(189677,6958,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(189678,6958,'content_blocks_14_images_0_header',''),(189679,6958,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(189680,6958,'content_blocks_14_images_0_description','Figure 9 - Check Valve Body cross-section'),(189681,6958,'_content_blocks_14_images_0_description','field_6170d90398010'),(189682,6958,'content_blocks_14_images_1_image','2989'),(189683,6958,'_content_blocks_14_images_1_image','field_6170d8e99800e'),(189684,6958,'content_blocks_14_images_1_header',''),(189685,6958,'_content_blocks_14_images_1_header','field_6170d8f49800f'),(189686,6958,'content_blocks_14_images_1_description','Figure 10 - Check Valve Body'),(189687,6958,'_content_blocks_14_images_1_description','field_6170d90398010'),(189688,6958,'content_blocks_14_images','3'),(189689,6958,'_content_blocks_14_images','field_6170d8df9800d'),(189690,6958,'content_blocks_14_images_2_image','2991'),(189691,6958,'_content_blocks_14_images_2_image','field_6170d8e99800e'),(189692,6958,'content_blocks_14_images_2_header',''),(189693,6958,'_content_blocks_14_images_2_header','field_6170d8f49800f'),(189694,6958,'content_blocks_14_images_2_description','Figure 11 - View of upper portion of intensifier cabinet'),(189695,6958,'_content_blocks_14_images_2_description','field_6170d90398010'),(189696,6958,'content_blocks_15_header','End Cap'),(189697,6958,'_content_blocks_15_header','field_6170d8ba9800b'),(189698,6958,'content_blocks_15_description','The end cap (number 9 in Figures 11 and 2) is either a cylindrical or square item. The cylindrical version screws onto the output end of the high pressure cylinder. The square type is held in place with tie rods and bolts. The end cap has a hole in the center for the check valve and outlet body. It will also have a connection point for the incoming fresh water. The water flows through holes machined through the cap to line up with inlet holes in the check valve.'),(189699,6958,'_content_blocks_15_description','field_6170d8cd9800c'),(189700,6958,'content_blocks_15_images_0_image','2992'),(189701,6958,'_content_blocks_15_images_0_image','field_6170d8e99800e'),(189702,6958,'content_blocks_15_images_0_header',''),(189703,6958,'_content_blocks_15_images_0_header','field_6170d8f49800f'),(189704,6958,'content_blocks_15_images_0_description',''),(189705,6958,'_content_blocks_15_images_0_description','field_6170d90398010'),(189706,6958,'content_blocks_15_images','1'),(189707,6958,'_content_blocks_15_images','field_6170d8df9800d'),(189708,6958,'content_blocks_16_header','10. High pressure tubing'),(189709,6958,'_content_blocks_16_header','field_6170d8ba9800b'),(189710,6958,'content_blocks_16_description','High pressure 304 or 316 stainless steel tubing (number 10 in Figure 11) is attached to the outlet of each check valve. Common outer diameters are 0.25\", 0.313\", 0.375\" and 0.563\". Inner diameters range from 0.062\" to 0.312\". There is usually a flexible protective covering around the tube.\r\n\r\nThe high pressure tubing from the left hand high pressure cylinder will join together at some point with the high pressure tubing from the right hand cylinder. The high pressure tubing carries the pressurized water to the pressure attenuator. Additional high pressure tubing will channel the high pressure water to the cutting head.\r\n\r\nThe length, number of bends and other obstructions to flow (e.g. hand valves) in the high pressure tubing path must be taken into consideration when designing a high pressure waterjet system. Pressure will drop with each bend in the tubing. Also, as the distance between the pump and the cutting head increases, internal friction of the water as it drags against the inner walls will generate heat resulting in a loss of water pressure. This topic will be discussed in more detail in the Chapter 5 \"Pressure Drop in Tubing.\"'),(189711,6958,'_content_blocks_16_description','field_6170d8cd9800c'),(189712,6958,'content_blocks_16_images_0_image','2994'),(189713,6958,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(189714,6958,'content_blocks_16_images_0_header',''),(189715,6958,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(189716,6958,'content_blocks_16_images_0_description',''),(189717,6958,'_content_blocks_16_images_0_description','field_6170d90398010'),(189718,6958,'content_blocks_16_images','1'),(189719,6958,'_content_blocks_16_images','field_6170d8df9800d'),(189720,6958,'content_blocks_17_header','11. Pressure attenuator'),(189721,6958,'_content_blocks_17_header','field_6170d8ba9800b'),(189722,6958,'content_blocks_17_description','The pressure attenuator (number 11 in Figures 13 and 2) smoothes out variations in pressure after the high pressure water has exited the intensifier. With each reversal of cycle of the intensifier, there is a slight delay in the increase of water pressure in the opposite high pressure cylinder. This delay is due to: 1) reversal of motion where instantaneous velocity at the end of the stroke equals zero, and 2) mechanical delays of reversal. All of these factors can result in a drop in water pressure. Some manufacturers do use proprietary technology to reduce this pressure drop, which we suggest you investigate when selecting a pump. Generally, if a 50 HP pump can sustain a 0.014\" orifice at 60,000 psi continuous operating pressure, the implication is that this hydraulic pressure drop challenge will have been addressed.\r\n\r\nThe pressure attenuator (number 11 in Figures 13 and 2) smoothes out variations in pressure after the high pressure water has exited the intensifier. With each reversal of cycle of the intensifier, there is a slight delay in the increase of water pressure in the opposite high pressure cylinder. This delay is due to: 1) reversal of motion where instantaneous velocity at the end of the stroke equals zero, and 2) mechanical delays of reversal. All of these factors can result in a drop in water pressure. Some manufacturers do use proprietary technology to reduce this pressure drop, which we suggest you investigate when selecting a pump. Generally, if a 50 HP pump can sustain a 0.014\" orifice at 60,000 psi continuous operating pressure, the implication is that this hydraulic pressure drop challenge will have been addressed.\r\n\r\nFigure 14 shows the pressure fluctuations in the high pressure water line prior to the pressure accumulator. This shows a pressure change from high to low of almost 22,000 psi. So, for a 60,000 psi system, the high pressure water would be going from 60,000 psi to 40,000 psi after every stroke of the intensifier.\r\n\r\nIf this pressure fluctuation were not smoothed out by the pressure attenuator, cutting results at the work piece would be undesirable. There would be a significant line in the part with every stroke of the intensifier. Recall that any change in pressure results in a change in speed of the waterjet stream at the cutting head. This change in speed changes the speed at which the abrasive particles are moving and, therefore, the amount of force they will impart on the work piece. Lower pressure leads to less speed of the water which leads to less force of the abrasive which leads to slower cutting, or rougher edge quality.\r\n\r\nFortunately the pressure attenuator smoothes out these pressure spikes so that the water at the cutting head maintains a steady pressure, speed and cutting power.\r\n\r\n&nbsp;'),(189723,6958,'_content_blocks_17_description','field_6170d8cd9800c'),(189724,6958,'content_blocks_17_images_0_image','2995'),(189725,6958,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(189726,6958,'content_blocks_17_images_0_header',''),(189727,6958,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(189728,6958,'content_blocks_17_images_0_description','Figure 13 - Pressure Attenuator'),(189729,6958,'_content_blocks_17_images_0_description','field_6170d90398010'),(189730,6958,'content_blocks_17_images_1_image','2996'),(189731,6958,'_content_blocks_17_images_1_image','field_6170d8e99800e'),(189732,6958,'content_blocks_17_images_1_header',''),(189733,6958,'_content_blocks_17_images_1_header','field_6170d8f49800f'),(189734,6958,'content_blocks_17_images_1_description','Figure 14 - Pressure fluctuation prior to accumulator\r\n\r\nSource: \"Pressure and Flow Rate Fluctuations at High Pressure Intensifier Pumps\", F. Trieb, et.al., 2007 American WJTA Conference and Expo'),(189735,6958,'_content_blocks_17_images_1_description','field_6170d90398010'),(189736,6958,'content_blocks_17_images','2'),(189737,6958,'_content_blocks_17_images','field_6170d8df9800d'),(189738,6958,'content_blocks_18_header','12. Inlet water'),(189739,6958,'_content_blocks_18_header','field_6170d8ba9800b'),(189740,6958,'content_blocks_18_description','Prior to entering the pump cabinet, water may have to be treated to get the water within the waterjet manufacturer’s specifications. Within the pump cabinet, usually in the lower portion, the water will typically go through one or more final filters just prior to entering the intensifier (number 12 in Figures 15 and 2).\r\n\r\nThe inlet water must be able to maintain a specified flow rate and pressure to ensure that the intensifier receives enough water. Incoming water must also meet certain requirements with respect to Total Dissolved Solids (TDS), pH, organic matter, temperature, etc. Poor water quality will result in drastically reduced high pressure component life (i.e. anything the high pressure water comes in contact with). Different pump manufacturers require different inlet water pressures, with some needing as little as 30 psi, and others mandating a water pressure booster pump to maintain 100 psi. Water quality will be discussed in more detail in the chapter 4 \"Water Quality.\"'),(189741,6958,'_content_blocks_18_description','field_6170d8cd9800c'),(189742,6958,'content_blocks_18_images_0_image',''),(189743,6958,'_content_blocks_18_images_0_image','field_6170d8e99800e'),(189744,6958,'content_blocks_18_images_0_header',''),(189745,6958,'_content_blocks_18_images_0_header','field_6170d8f49800f'),(189746,6958,'content_blocks_18_images_0_description','Figure 15 - Inlet water filters'),(189747,6958,'_content_blocks_18_images_0_description','field_6170d90398010'),(189748,6958,'content_blocks_18_images','1'),(189749,6958,'_content_blocks_18_images','field_6170d8df9800d'),(189750,6958,'content_blocks_19_header','13. Controls and PLC'),(189751,6958,'_content_blocks_19_header','field_6170d8ba9800b'),(189752,6958,'content_blocks_19_description','The controls and PLC (not pictured) control the valves in the hydraulic circuit to determine the pressure and flow of the hydraulic oil to and from the intensifier. Various sensor and proximity switches can also be integrated into the controls to monitor the entire pump to verify things like stroke rate, oil temperature and pressure, inlet water pressure and flow rate and more. This capability makes working with and troubleshooting the modern day intensifier much easier.\r\n\r\nThe pneumatic On-Off valve controls the flow of water to the cutting head. The On-Off valve at the cutting is \"normally closed.\" That is, when there is no compressed air supplied to the On-Off valve, a needle fits tightly against a seat to stop any high pressure water from getting to the cutting head. When compressed air is supplied to the On-Off valve (i.e. \"tool on\" command from the control), the needle is forced up from its seating location and the high pressure water can flow through the orifice to the cutting head.\r\n\r\nIn, or near, the high pressure pump cabinet is another On-Off valve that works in tandem with the On-Off valve at the cutting head. The On-Off valve in the pump is typically called the Safety Relief valve. This Safety Relief valve in the pump is \"normally open.\" This valve will stay open when there is no air supplied to it. When the On-Off valve at the cutting head closes (\"tool off\" command by control or no power to the system), the Safety Relief valve in the pump will open, relieving all water pressure from the high pressure tubing. When the \"tool on\" command is issued by the control, the Safety Relief valve closes so that all high pressure water will go to the cutting head. Note, not all manufacturers of new pumps have the Safety Relief valve as standard. We strongly suggest you ask your pump manufacturer if they supply this standard, and when it is activated. Again, some pump manufacturers will only activate the Safety Valve when an E-Stop is pressed; when the pump stops, high pressure lines are still pressurized.\r\n\r\nBoth of these On-Off valves must be in good working order to protect against accidental high pressure water discharge at the cutting head that could severely injure someone working on or near the cutting head or any of the high pressure lines. Periodic replacement of the needle, seat and associated parts is required to maintain these valves.'),(189753,6958,'_content_blocks_19_description','field_6170d8cd9800c'),(189754,6958,'content_blocks_19_images_0_image','2997'),(189755,6958,'_content_blocks_19_images_0_image','field_6170d8e99800e'),(189756,6958,'content_blocks_19_images_0_header',''),(189757,6958,'_content_blocks_19_images_0_header','field_6170d8f49800f'),(189758,6958,'content_blocks_19_images_0_description',''),(189759,6958,'_content_blocks_19_images_0_description','field_6170d90398010'),(189760,6958,'content_blocks_19_images','1'),(189761,6958,'_content_blocks_19_images','field_6170d8df9800d'),(189762,6958,'content_blocks_20_header','Abrasive feeding system'),(189763,6958,'_content_blocks_20_header','field_6170d8ba9800b'),(189764,6958,'content_blocks_20_description',''),(189765,6958,'_content_blocks_20_description','field_6170d8cd9800c'),(189766,6958,'content_blocks_20_images',''),(189767,6958,'_content_blocks_20_images','field_6170d8df9800d'),(189768,6958,'content_blocks_21_header','Pressurized Bulk hopper'),(189769,6958,'_content_blocks_21_header','field_6170d8ba9800b'),(189770,6958,'content_blocks_21_description','Abrasive is transported via tubing and pressure from a large bulk hopper located near the waterjet cutting system to a mini-hopper near the cutting head. Bulk hoppers will normally hold anywhere from several hundred pounds of abrasive to 2200 pounds. If you are cutting with one head and 1.4 pounds per minute of abrasive, then you are consuming about 84 pounds per hour. An 1100 pound hopper would last about 13 hours of operation. This would mean that the machine could run for well over a shift before it needed to be refilled. Most waterjets are provided with approximately 600 pound hoppers, which would equate to about 7 hours of operation. So, at least once during an 8 hour shift the hopper would need to be reloaded. The costs associated with the additional downtime over the course of a year should be evaluated.\r\n\r\n&nbsp;'),(189771,6958,'_content_blocks_21_description','field_6170d8cd9800c'),(189772,6958,'content_blocks_21_images_0_image','4124'),(189773,6958,'_content_blocks_21_images_0_image','field_6170d8e99800e'),(189774,6958,'content_blocks_21_images_0_header',''),(189775,6958,'_content_blocks_21_images_0_header','field_6170d8f49800f'),(189776,6958,'content_blocks_21_images_0_description',''),(189777,6958,'_content_blocks_21_images_0_description','field_6170d90398010'),(189778,6958,'content_blocks_21_images','1'),(189779,6958,'_content_blocks_21_images','field_6170d8df9800d'),(189780,6958,'content_blocks_22_header','Mini Hopper'),(189781,6958,'_content_blocks_22_header','field_6170d8ba9800b'),(189782,6958,'content_blocks_22_description','A mini-hopper is typically mounted near and above the cutting head. Most of these mini-hoppers allow for a gravity feed of abrasive down to the cutting head. Many mini-hoppers control the amount of abrasive that can go down to the cutting head with the use of a slide with different size holes in it. The operator can change the position of the slide to change the amount of abrasive to the cutting head.\r\n\r\nA recent advance in technology is remote CNC-control of the amount of abrasive released from the mini-hopper. Having this capability allows for optimum feeding of abrasive to the cutting head in relation to the water pressure at the pump for the following desirable capabilities:\r\n<ul>\r\n 	<li>Piercing of fragile materials like glass or stone. Typically a lower water pressure will be used with a smaller amount of abrasive</li>\r\n 	<li>Changing abrasive amount for different abrasive nozzle sizes to optimize part cost. This can be done automatically if the mini hopper is set up to do this.</li>\r\n</ul>'),(189783,6958,'_content_blocks_22_description','field_6170d8cd9800c'),(189784,6958,'content_blocks_22_images_0_image','4125'),(189785,6958,'_content_blocks_22_images_0_image','field_6170d8e99800e'),(189786,6958,'content_blocks_22_images_0_header',''),(189787,6958,'_content_blocks_22_images_0_header','field_6170d8f49800f'),(189788,6958,'content_blocks_22_images_0_description',''),(189789,6958,'_content_blocks_22_images_0_description','field_6170d90398010'),(189790,6958,'content_blocks_22_images','1'),(189791,6958,'_content_blocks_22_images','field_6170d8df9800d'),(189792,6958,'content_blocks_23_header','Summary'),(189793,6958,'_content_blocks_23_header','field_6170d8ba9800b'),(189794,6958,'content_blocks_23_description','In this chapter, after a brief review of the waterjet cutting process, we looked at the two different style pumps that are used in high pressure waterjet cutting: intensifier and direct drive and covered a few of the advantages of each pump style. The water pressurization process of an intensifier pump was detailed. We went through the different parts of an intensifier pump so that you will have a good idea what a sales person or technician is talking about when they refer to a part in a pump. We also discussed the On-Off valve and how it is used at the cutting head and in the pump. The abrasive feeding system was discussed, as well as the merits of a CNC-controlled abrasive metering system.\r\n\r\n&nbsp;\r\n\r\n[devvn_ihotspot id=\"4348\"]\r\n\r\n[devvn_ihotspot id=\"4350\"]'),(189795,6958,'_content_blocks_23_description','field_6170d8cd9800c'),(189796,6958,'content_blocks_23_images',''),(189797,6958,'_content_blocks_23_images','field_6170d8df9800d'),(189798,2970,'_wpml_media_has_media','1'),(189803,6960,'hero_gallery',''),(189804,6960,'_hero_gallery','field_60c23d554e4a3'),(189805,6960,'hero_banner','6959'),(189806,6960,'_hero_banner','field_6170dbe179470'),(189807,6960,'page_title','Overview'),(189808,6960,'_page_title','field_6170d88998008'),(189809,6960,'page_description','This chapter will discuss water quality requirements for high pressure waterjet cutting and why it is crucial to maintain proper water quality.\r\n\r\nNote: See \"Recommendation for water treatment\" at the end of this chapter for a potential solution to everything you are about to read in this chapter about water treatment.'),(189810,6960,'_page_description','field_6170d89398009'),(189811,6960,'content_blocks','11'),(189812,6960,'_content_blocks','field_6170d8ac9800a'),(189813,6960,'menu','37'),(189814,6960,'_menu','field_6170d9e059837'),(189815,6960,'display_left_column','1'),(189816,6960,'_display_left_column','field_613563c4d424b'),(189817,6960,'contact_left_heading',''),(189818,6960,'_contact_left_heading','field_60c249d645c99'),(189819,6960,'contact_left_copy',''),(189820,6960,'_contact_left_copy','field_60c24a0845c9c'),(189821,6960,'display_right_column','1'),(189822,6960,'_display_right_column','field_613563f4d424c'),(189823,6960,'contact_right_heading',''),(189824,6960,'_contact_right_heading','field_60c249e945c9a'),(189825,6960,'contact_right_copy',''),(189826,6960,'_contact_right_copy','field_60c249f845c9b'),(189827,6960,'contact_right_cta',''),(189828,6960,'_contact_right_cta','field_60c24a1945c9d'),(189829,6960,'content_blocks_0_header','Water Specifications'),(189830,6960,'_content_blocks_0_header','field_6170d8ba9800b'),(189831,6960,'content_blocks_0_description','Every manufacturer has specific requirements for water quality. Check with the manufacturer to get the specifications for your particular machine.\r\n\r\nThe water supplied to the intensifier is critical to waterjet cutting due to its direct influence on the service life of the equipment components such as check valves, seals and orifices. A high concentration of Total Dissolved Solids (TDS) causes accelerated wear of any components that come in contact with the high pressure water because of the increased abrasiveness of the water from the TDS.\r\n\r\nAs part of the installation planning, a water quality analysis should be performed by a commercial company that specializes in water conditioning equipment. The minimum information that should be supplied by this analysis is TDS, silica content and pH value. Companies like Culligan can perform these tests, or you can search \"water quality testing\" on the internet.\r\n\r\nInlet water should be treated for either the removal of hardness of the reduction of TDS. Water softening is an ion exchange process that removes scale forming minerals such as calcium. TDS reduction can be accomplished with either deionization (DI) or reverse osmosis equipment. Generally, DI or RO provides better component life than water softening.\r\n\r\nA water purification supplier should be consulted to supply the most suitable equipment for special conditions. It might be a good idea to ask any company that you are considering using if they have supplied systems for any other high pressure waterjet cutting systems and check their references.\r\n\r\nThe best treatment process for a specific application is a function of the original water quality and the desired service life of the affected components. Sixty to 70 ppm of TDS is optimum. Any water treatment producing TDS content of less than 0.5 part per million (ppm) should be avoided since the aggressiveness of such purified water will damage pump components.'),(189832,6960,'_content_blocks_0_description','field_6170d8cd9800c'),(189833,6960,'content_blocks_0_images',''),(189834,6960,'_content_blocks_0_images','field_6170d8df9800d'),(189835,6960,'content_blocks_1_header','Water Treatment Guidelines'),(189836,6960,'_content_blocks_1_header','field_6170d8ba9800b'),(189837,6960,'content_blocks_1_description','<table class=\"table table-bordered table-hover table-striped table-responsive\">\r\n<thead>\r\n<tr>\r\n<th>Criteria</th>\r\n<th>Values</th>\r\n<th>Recommended Treatment</th>\r\n</tr>\r\n</thead>\r\n<tbody>\r\n<tr>\r\n<td>Total Dissolved Solids (TDS)</td>\r\n<td>Low TDS (&lt;100 ppm)\r\nModerate TDS (100 - 200 ppm)\r\nHigh TDS (&gt;200 ppm)</td>\r\n<td>Good water, requires only softening\r\nCan be treated by softening, DI or RO\r\nPoor water, should be treated with RO or DI</td>\r\n</tr>\r\n<tr>\r\n<td>Silica Content</td>\r\n<td>High content (&gt;15 ppm)</td>\r\n<td>Dual Bed Strong Base DI</td>\r\n</tr>\r\n<tr>\r\n<td>pH Value</td>\r\n<td>Treated water must have a value of 6 - 8</td>\r\n</tr>\r\n</tbody>\r\n</table>'),(189838,6960,'_content_blocks_1_description','field_6170d8cd9800c'),(189839,6960,'content_blocks_1_images',''),(189840,6960,'_content_blocks_1_images','field_6170d8df9800d'),(189841,6960,'content_blocks_2_header','Suspended Solids'),(189842,6960,'_content_blocks_2_header','field_6170d8ba9800b'),(189843,6960,'content_blocks_2_description','In addition to the treatment described above, the water must be filtered for the removal of suspended solids. Different manufacturers supply differently sized final filters for this purpose, typically down to 0.45 nominal. See \"Recommendation for water treatment\" at the end of this chapter for an alternative to this.'),(189844,6960,'_content_blocks_2_description','field_6170d8cd9800c'),(189845,6960,'content_blocks_2_images',''),(189846,6960,'_content_blocks_2_images','field_6170d8df9800d'),(189847,6960,'content_blocks_3_header','Water Supply'),(189848,6960,'_content_blocks_3_header','field_6170d8ba9800b'),(189849,6960,'content_blocks_3_description','The initial water supply should be at least 5 gallons per minute at 40 pounds per square inch. The water may be boosted by a small pump to the 80 psi required by most intensifiers. Some intensifiers do not require pressure boosters, requiring only 30 psi for the incoming water. This removes a potential failure point from the system.'),(189850,6960,'_content_blocks_3_description','field_6170d8cd9800c'),(189851,6960,'content_blocks_3_images',''),(189852,6960,'_content_blocks_3_images','field_6170d8df9800d'),(189853,6960,'content_blocks_4_header','Hydraulic Oil Cooling'),(189854,6960,'_content_blocks_4_header','field_6170d8ba9800b'),(189855,6960,'content_blocks_4_description','Intensifier pumps have hydraulic oil that must be cooled. Typically there are three options:\r\n<ol>\r\n 	<li>Water-Cooled through a heat exchanger</li>\r\n 	<li>Air-Over-Oil Cooler</li>\r\n 	<li>Closed-Loop Chiller</li>\r\n</ol>'),(189856,6960,'_content_blocks_4_description','field_6170d8cd9800c'),(189857,6960,'content_blocks_4_images',''),(189858,6960,'_content_blocks_4_images','field_6170d8df9800d'),(189859,6960,'content_blocks_5_header','1. Heat exchanger - For water cooled pumps'),(189860,6960,'_content_blocks_5_header','field_6170d8ba9800b'),(189861,6960,'content_blocks_5_description','A heat exchanger is primarily used for cooling the hydraulic fluid of the intensifier pump. Typically the hydraulic oil temperature must be kept below 120° F (49° C). The heat exchanger will require a consistent water flow of 0 to 8 gpm (0 to 30 liters per minute) at an inlet temperature not exceeding 70° F in order to keep the hydraulic fluid at the proper temperature. Actual volume of water will depend on the pump selected. As many pumps are thermostatically controlled, when the pump is cool, it may be that no water is required.\r\n\r\nThis cooling water must go to drain. The cost of this water must be balanced against the costs of the other two cooling options (air-over-oil and chiller), which would not have any water going down the drain.\r\n\r\nPublic utility water is usually acceptable for cooling purposes. In situations where the water contains heavy mineral deposits, the exchanger tubes may eventually become restricted by particle buildup. If this is a chronic problem, pre-filtration and/or water softening may be necessary.\r\n\r\nDepending upon plant setup, ambient temperature can also be a factor in cooling the hydraulic fluid. Additional cooling may be required if the intensifier and/or heat exchanger is confined to a small, high-temperature space.'),(189862,6960,'_content_blocks_5_description','field_6170d8cd9800c'),(189863,6960,'content_blocks_5_images_0_image','4128'),(189864,6960,'_content_blocks_5_images_0_image','field_6170d8e99800e'),(189865,6960,'content_blocks_5_images_0_header',''),(189866,6960,'_content_blocks_5_images_0_header','field_6170d8f49800f'),(189867,6960,'content_blocks_5_images_0_description','Figure 1 - View of heat exchanger'),(189868,6960,'_content_blocks_5_images_0_description','field_6170d90398010'),(189869,6960,'content_blocks_5_images','1'),(189870,6960,'_content_blocks_5_images','field_6170d8df9800d'),(189871,6960,'content_blocks_6_header','2. Air-Over-Oil Cooler'),(189872,6960,'_content_blocks_6_header','field_6170d8ba9800b'),(189873,6960,'content_blocks_6_description','Some pumps will use an oil-air cooler to remove heat from the hydraulic oil, so no heat exchanger is required. In the summer, the unit can be vented outside the building to remove the heat from the building. In the winter it can be vented inside the building to help out with heating the building.'),(189874,6960,'_content_blocks_6_description','field_6170d8cd9800c'),(189875,6960,'content_blocks_6_images_0_image','4129'),(189876,6960,'_content_blocks_6_images_0_image','field_6170d8e99800e'),(189877,6960,'content_blocks_6_images_0_header',''),(189878,6960,'_content_blocks_6_images_0_header','field_6170d8f49800f'),(189879,6960,'content_blocks_6_images_0_description',''),(189880,6960,'_content_blocks_6_images_0_description','field_6170d90398010'),(189881,6960,'content_blocks_6_images','1'),(189882,6960,'_content_blocks_6_images','field_6170d8df9800d'),(189883,6960,'content_blocks_7_header','3. Chiller'),(189884,6960,'_content_blocks_7_header','field_6170d8ba9800b'),(189885,6960,'content_blocks_7_description','A chiller can be used to re-circulate the cooling water that is used by the intensifier\'s heat exchanger. It cools the water and then sends it through the heat exchanger again, creating a closed loop. A chiller is most effective in worth considering in a few situations in particular:\r\n<ul>\r\n 	<li>Warmer climates where the efficiency of the heat exchanger may be reduce</li>\r\n 	<li>Facilities that cannot send any water to a drain</li>\r\n 	<li>Parts of the country where there is a water shortage, or if the cost of water is high, because a 50 HP pump can use up to 5 gpm for cooling the hydraulics</li>\r\n</ul>\r\nThe chiller will only reuse the cooling water; you will still be putting approximately 1 gpm with a 50 hp pump of fresh water through the cutting head, which will not be reused with the chiller.\r\n\r\nIncoming water for the intensifier should also be maintained at 70° F (21° C) or cooler for best high pressure seal life. If this temperature cannot be maintained, then the chiller can also be used for this water.'),(189886,6960,'_content_blocks_7_description','field_6170d8cd9800c'),(189887,6960,'content_blocks_7_images_0_image','4130'),(189888,6960,'_content_blocks_7_images_0_image','field_6170d8e99800e'),(189889,6960,'content_blocks_7_images_0_header',''),(189890,6960,'_content_blocks_7_images_0_header','field_6170d8f49800f'),(189891,6960,'content_blocks_7_images_0_description',''),(189892,6960,'_content_blocks_7_images_0_description','field_6170d90398010'),(189893,6960,'content_blocks_7_images','1'),(189894,6960,'_content_blocks_7_images','field_6170d8df9800d'),(189895,6960,'content_blocks_8_header','Filtering of Drain Water'),(189896,6960,'_content_blocks_8_header','field_6170d8ba9800b'),(189897,6960,'content_blocks_8_description','If you have water from the waterjet tank going to drain, you will have suspended solids in this water (abrasive and small amounts of kerf material). To avoid the potential of clogging up sewer lines, this water should run through some sort of filter or weir tank to get as much suspended solids as possible out of the drain water. The filter could be as simple as a sock filter. Sock filters are available in various micron sizes. Something like a paper bed filter can have a roll of filter media that is continually advanced as the drain water passes through it.'),(189898,6960,'_content_blocks_8_description','field_6170d8cd9800c'),(189899,6960,'content_blocks_8_images_0_image','4131'),(189900,6960,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(189901,6960,'content_blocks_8_images_0_header',''),(189902,6960,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(189903,6960,'content_blocks_8_images_0_description',''),(189904,6960,'_content_blocks_8_images_0_description','field_6170d90398010'),(189905,6960,'content_blocks_8_images','1'),(189906,6960,'_content_blocks_8_images','field_6170d8df9800d'),(189907,6960,'content_blocks_9_header','Water circuit options'),(189908,6960,'_content_blocks_9_header','field_6170d8ba9800b'),(189909,6960,'content_blocks_9_description','Following are 4 different scenarios for the water flow through a waterjet cutting system.'),(189910,6960,'_content_blocks_9_description','field_6170d8cd9800c'),(189911,6960,'content_blocks_9_images_0_image','4132'),(189912,6960,'_content_blocks_9_images_0_image','field_6170d8e99800e'),(189913,6960,'content_blocks_9_images_0_header','Option 1'),(189914,6960,'_content_blocks_9_images_0_header','field_6170d8f49800f'),(189915,6960,'content_blocks_9_images_0_description','Heat exchanger in pump, all water runs to a drain.\r\n\r\n'),(189916,6960,'_content_blocks_9_images_0_description','field_6170d90398010'),(189917,6960,'content_blocks_9_images_1_image','4133'),(189918,6960,'_content_blocks_9_images_1_image','field_6170d8e99800e'),(189919,6960,'content_blocks_9_images_1_header','Option 2'),(189920,6960,'_content_blocks_9_images_1_header','field_6170d8f49800f'),(189921,6960,'content_blocks_9_images_1_description','Air-Over-Oil cooler'),(189922,6960,'_content_blocks_9_images_1_description','field_6170d90398010'),(189923,6960,'content_blocks_9_images_2_image',''),(189924,6960,'_content_blocks_9_images_2_image','field_6170d8e99800e'),(189925,6960,'content_blocks_9_images_2_header','Option 3'),(189926,6960,'_content_blocks_9_images_2_header','field_6170d8f49800f'),(189927,6960,'content_blocks_9_images_2_description','Chiller and heat exchanger. Water for heat exchanger re-circulates; used water from cutting runs to drain.'),(189928,6960,'_content_blocks_9_images_2_description','field_6170d90398010'),(189929,6960,'content_blocks_9_images_3_image','4134'),(189930,6960,'_content_blocks_9_images_3_image','field_6170d8e99800e'),(189931,6960,'content_blocks_9_images_3_header','Option 4'),(189932,6960,'_content_blocks_9_images_3_header','field_6170d8f49800f'),(189933,6960,'content_blocks_9_images_3_description','Heat exchanger, chiller and WRS-3000 water recycling unit. No water to drain. Only water required is make-up water to replace evaporation and spillage.'),(189934,6960,'_content_blocks_9_images_3_description','field_6170d90398010'),(189935,6960,'content_blocks_9_images','4'),(189936,6960,'_content_blocks_9_images','field_6170d8df9800d'),(189937,6960,'content_blocks_10_header','Recommendation for Water Treatment'),(189938,6960,'_content_blocks_10_header','field_6170d8ba9800b'),(189939,6960,'content_blocks_10_description','WARDJet has found that the use of a good quality water softener in conjunction with a 0.2 absolute final filter to be successful for treatment of water for the intensifier. This setup can be used as long as the water from the cutting tank is not being recycled for use through the intensifier. In the worst case, if seal life does not seem to be living up to expectations, then a DI or RO system can be installed.'),(189940,6960,'_content_blocks_10_description','field_6170d8cd9800c'),(189941,6960,'content_blocks_10_images',''),(189942,6960,'_content_blocks_10_images','field_6170d8df9800d'),(189944,4144,'_thumbnail_id','6935'),(189945,6961,'hero_gallery',''),(189946,6961,'_hero_gallery','field_60c23d554e4a3'),(189947,6961,'hero_banner','6935'),(189948,6961,'_hero_banner','field_6170dbe179470'),(189949,6961,'page_title','Overview'),(189950,6961,'_page_title','field_6170d88998008'),(189951,6961,'page_description','This chapter will discuss water quality requirements for high pressure waterjet cutting and why it is crucial to maintain proper water quality.\r\n\r\nNote: See \"Recommendation for water treatment\" at the end of this chapter for a potential solution to everything you are about to read in this chapter about water treatment.'),(189952,6961,'_page_description','field_6170d89398009'),(189953,6961,'content_blocks','11'),(189954,6961,'_content_blocks','field_6170d8ac9800a'),(189955,6961,'menu','37'),(189956,6961,'_menu','field_6170d9e059837'),(189957,6961,'display_left_column','1'),(189958,6961,'_display_left_column','field_613563c4d424b'),(189959,6961,'contact_left_heading',''),(189960,6961,'_contact_left_heading','field_60c249d645c99'),(189961,6961,'contact_left_copy',''),(189962,6961,'_contact_left_copy','field_60c24a0845c9c'),(189963,6961,'display_right_column','1'),(189964,6961,'_display_right_column','field_613563f4d424c'),(189965,6961,'contact_right_heading',''),(189966,6961,'_contact_right_heading','field_60c249e945c9a'),(189967,6961,'contact_right_copy',''),(189968,6961,'_contact_right_copy','field_60c249f845c9b'),(189969,6961,'contact_right_cta',''),(189970,6961,'_contact_right_cta','field_60c24a1945c9d'),(189971,6961,'content_blocks_0_header','Water Specifications'),(189972,6961,'_content_blocks_0_header','field_6170d8ba9800b'),(189973,6961,'content_blocks_0_description','Every manufacturer has specific requirements for water quality. Check with the manufacturer to get the specifications for your particular machine.\r\n\r\nThe water supplied to the intensifier is critical to waterjet cutting due to its direct influence on the service life of the equipment components such as check valves, seals and orifices. A high concentration of Total Dissolved Solids (TDS) causes accelerated wear of any components that come in contact with the high pressure water because of the increased abrasiveness of the water from the TDS.\r\n\r\nAs part of the installation planning, a water quality analysis should be performed by a commercial company that specializes in water conditioning equipment. The minimum information that should be supplied by this analysis is TDS, silica content and pH value. Companies like Culligan can perform these tests, or you can search \"water quality testing\" on the internet.\r\n\r\nInlet water should be treated for either the removal of hardness of the reduction of TDS. Water softening is an ion exchange process that removes scale forming minerals such as calcium. TDS reduction can be accomplished with either deionization (DI) or reverse osmosis equipment. Generally, DI or RO provides better component life than water softening.\r\n\r\nA water purification supplier should be consulted to supply the most suitable equipment for special conditions. It might be a good idea to ask any company that you are considering using if they have supplied systems for any other high pressure waterjet cutting systems and check their references.\r\n\r\nThe best treatment process for a specific application is a function of the original water quality and the desired service life of the affected components. Sixty to 70 ppm of TDS is optimum. Any water treatment producing TDS content of less than 0.5 part per million (ppm) should be avoided since the aggressiveness of such purified water will damage pump components.'),(189974,6961,'_content_blocks_0_description','field_6170d8cd9800c'),(189975,6961,'content_blocks_0_images',''),(189976,6961,'_content_blocks_0_images','field_6170d8df9800d'),(189977,6961,'content_blocks_1_header','Water Treatment Guidelines'),(189978,6961,'_content_blocks_1_header','field_6170d8ba9800b'),(189979,6961,'content_blocks_1_description','<table class=\"table table-bordered table-hover table-striped table-responsive\">\r\n<thead>\r\n<tr>\r\n<th>Criteria</th>\r\n<th>Values</th>\r\n<th>Recommended Treatment</th>\r\n</tr>\r\n</thead>\r\n<tbody>\r\n<tr>\r\n<td>Total Dissolved Solids (TDS)</td>\r\n<td>Low TDS (&lt;100 ppm)\r\nModerate TDS (100 - 200 ppm)\r\nHigh TDS (&gt;200 ppm)</td>\r\n<td>Good water, requires only softening\r\nCan be treated by softening, DI or RO\r\nPoor water, should be treated with RO or DI</td>\r\n</tr>\r\n<tr>\r\n<td>Silica Content</td>\r\n<td>High content (&gt;15 ppm)</td>\r\n<td>Dual Bed Strong Base DI</td>\r\n</tr>\r\n<tr>\r\n<td>pH Value</td>\r\n<td>Treated water must have a value of 6 - 8</td>\r\n</tr>\r\n</tbody>\r\n</table>'),(189980,6961,'_content_blocks_1_description','field_6170d8cd9800c'),(189981,6961,'content_blocks_1_images',''),(189982,6961,'_content_blocks_1_images','field_6170d8df9800d'),(189983,6961,'content_blocks_2_header','Suspended Solids'),(189984,6961,'_content_blocks_2_header','field_6170d8ba9800b'),(189985,6961,'content_blocks_2_description','In addition to the treatment described above, the water must be filtered for the removal of suspended solids. Different manufacturers supply differently sized final filters for this purpose, typically down to 0.45 nominal. See \"Recommendation for water treatment\" at the end of this chapter for an alternative to this.'),(189986,6961,'_content_blocks_2_description','field_6170d8cd9800c'),(189987,6961,'content_blocks_2_images',''),(189988,6961,'_content_blocks_2_images','field_6170d8df9800d'),(189989,6961,'content_blocks_3_header','Water Supply'),(189990,6961,'_content_blocks_3_header','field_6170d8ba9800b'),(189991,6961,'content_blocks_3_description','The initial water supply should be at least 5 gallons per minute at 40 pounds per square inch. The water may be boosted by a small pump to the 80 psi required by most intensifiers. Some intensifiers do not require pressure boosters, requiring only 30 psi for the incoming water. This removes a potential failure point from the system.'),(189992,6961,'_content_blocks_3_description','field_6170d8cd9800c'),(189993,6961,'content_blocks_3_images',''),(189994,6961,'_content_blocks_3_images','field_6170d8df9800d'),(189995,6961,'content_blocks_4_header','Hydraulic Oil Cooling'),(189996,6961,'_content_blocks_4_header','field_6170d8ba9800b'),(189997,6961,'content_blocks_4_description','Intensifier pumps have hydraulic oil that must be cooled. Typically there are three options:\r\n<ol>\r\n 	<li>Water-Cooled through a heat exchanger</li>\r\n 	<li>Air-Over-Oil Cooler</li>\r\n 	<li>Closed-Loop Chiller</li>\r\n</ol>'),(189998,6961,'_content_blocks_4_description','field_6170d8cd9800c'),(189999,6961,'content_blocks_4_images',''),(190000,6961,'_content_blocks_4_images','field_6170d8df9800d'),(190001,6961,'content_blocks_5_header','1. Heat exchanger - For water cooled pumps'),(190002,6961,'_content_blocks_5_header','field_6170d8ba9800b'),(190003,6961,'content_blocks_5_description','A heat exchanger is primarily used for cooling the hydraulic fluid of the intensifier pump. Typically the hydraulic oil temperature must be kept below 120° F (49° C). The heat exchanger will require a consistent water flow of 0 to 8 gpm (0 to 30 liters per minute) at an inlet temperature not exceeding 70° F in order to keep the hydraulic fluid at the proper temperature. Actual volume of water will depend on the pump selected. As many pumps are thermostatically controlled, when the pump is cool, it may be that no water is required.\r\n\r\nThis cooling water must go to drain. The cost of this water must be balanced against the costs of the other two cooling options (air-over-oil and chiller), which would not have any water going down the drain.\r\n\r\nPublic utility water is usually acceptable for cooling purposes. In situations where the water contains heavy mineral deposits, the exchanger tubes may eventually become restricted by particle buildup. If this is a chronic problem, pre-filtration and/or water softening may be necessary.\r\n\r\nDepending upon plant setup, ambient temperature can also be a factor in cooling the hydraulic fluid. Additional cooling may be required if the intensifier and/or heat exchanger is confined to a small, high-temperature space.'),(190004,6961,'_content_blocks_5_description','field_6170d8cd9800c'),(190005,6961,'content_blocks_5_images_0_image','4128'),(190006,6961,'_content_blocks_5_images_0_image','field_6170d8e99800e'),(190007,6961,'content_blocks_5_images_0_header',''),(190008,6961,'_content_blocks_5_images_0_header','field_6170d8f49800f'),(190009,6961,'content_blocks_5_images_0_description','Figure 1 - View of heat exchanger'),(190010,6961,'_content_blocks_5_images_0_description','field_6170d90398010'),(190011,6961,'content_blocks_5_images','1'),(190012,6961,'_content_blocks_5_images','field_6170d8df9800d'),(190013,6961,'content_blocks_6_header','2. Air-Over-Oil Cooler'),(190014,6961,'_content_blocks_6_header','field_6170d8ba9800b'),(190015,6961,'content_blocks_6_description','Some pumps will use an oil-air cooler to remove heat from the hydraulic oil, so no heat exchanger is required. In the summer, the unit can be vented outside the building to remove the heat from the building. In the winter it can be vented inside the building to help out with heating the building.'),(190016,6961,'_content_blocks_6_description','field_6170d8cd9800c'),(190017,6961,'content_blocks_6_images_0_image','4129'),(190018,6961,'_content_blocks_6_images_0_image','field_6170d8e99800e'),(190019,6961,'content_blocks_6_images_0_header',''),(190020,6961,'_content_blocks_6_images_0_header','field_6170d8f49800f'),(190021,6961,'content_blocks_6_images_0_description',''),(190022,6961,'_content_blocks_6_images_0_description','field_6170d90398010'),(190023,6961,'content_blocks_6_images','1'),(190024,6961,'_content_blocks_6_images','field_6170d8df9800d'),(190025,6961,'content_blocks_7_header','3. Chiller'),(190026,6961,'_content_blocks_7_header','field_6170d8ba9800b'),(190027,6961,'content_blocks_7_description','A chiller can be used to re-circulate the cooling water that is used by the intensifier\'s heat exchanger. It cools the water and then sends it through the heat exchanger again, creating a closed loop. A chiller is most effective in worth considering in a few situations in particular:\r\n<ul>\r\n 	<li>Warmer climates where the efficiency of the heat exchanger may be reduce</li>\r\n 	<li>Facilities that cannot send any water to a drain</li>\r\n 	<li>Parts of the country where there is a water shortage, or if the cost of water is high, because a 50 HP pump can use up to 5 gpm for cooling the hydraulics</li>\r\n</ul>\r\nThe chiller will only reuse the cooling water; you will still be putting approximately 1 gpm with a 50 hp pump of fresh water through the cutting head, which will not be reused with the chiller.\r\n\r\nIncoming water for the intensifier should also be maintained at 70° F (21° C) or cooler for best high pressure seal life. If this temperature cannot be maintained, then the chiller can also be used for this water.'),(190028,6961,'_content_blocks_7_description','field_6170d8cd9800c'),(190029,6961,'content_blocks_7_images_0_image','4130'),(190030,6961,'_content_blocks_7_images_0_image','field_6170d8e99800e'),(190031,6961,'content_blocks_7_images_0_header',''),(190032,6961,'_content_blocks_7_images_0_header','field_6170d8f49800f'),(190033,6961,'content_blocks_7_images_0_description',''),(190034,6961,'_content_blocks_7_images_0_description','field_6170d90398010'),(190035,6961,'content_blocks_7_images','1'),(190036,6961,'_content_blocks_7_images','field_6170d8df9800d'),(190037,6961,'content_blocks_8_header','Filtering of Drain Water'),(190038,6961,'_content_blocks_8_header','field_6170d8ba9800b'),(190039,6961,'content_blocks_8_description','If you have water from the waterjet tank going to drain, you will have suspended solids in this water (abrasive and small amounts of kerf material). To avoid the potential of clogging up sewer lines, this water should run through some sort of filter or weir tank to get as much suspended solids as possible out of the drain water. The filter could be as simple as a sock filter. Sock filters are available in various micron sizes. Something like a paper bed filter can have a roll of filter media that is continually advanced as the drain water passes through it.'),(190040,6961,'_content_blocks_8_description','field_6170d8cd9800c'),(190041,6961,'content_blocks_8_images_0_image','4131'),(190042,6961,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(190043,6961,'content_blocks_8_images_0_header',''),(190044,6961,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(190045,6961,'content_blocks_8_images_0_description',''),(190046,6961,'_content_blocks_8_images_0_description','field_6170d90398010'),(190047,6961,'content_blocks_8_images','1'),(190048,6961,'_content_blocks_8_images','field_6170d8df9800d'),(190049,6961,'content_blocks_9_header','Water circuit options'),(190050,6961,'_content_blocks_9_header','field_6170d8ba9800b'),(190051,6961,'content_blocks_9_description','Following are 4 different scenarios for the water flow through a waterjet cutting system.'),(190052,6961,'_content_blocks_9_description','field_6170d8cd9800c'),(190053,6961,'content_blocks_9_images_0_image','4132'),(190054,6961,'_content_blocks_9_images_0_image','field_6170d8e99800e'),(190055,6961,'content_blocks_9_images_0_header','Option 1'),(190056,6961,'_content_blocks_9_images_0_header','field_6170d8f49800f'),(190057,6961,'content_blocks_9_images_0_description','Heat exchanger in pump, all water runs to a drain.\r\n\r\n'),(190058,6961,'_content_blocks_9_images_0_description','field_6170d90398010'),(190059,6961,'content_blocks_9_images_1_image','4133'),(190060,6961,'_content_blocks_9_images_1_image','field_6170d8e99800e'),(190061,6961,'content_blocks_9_images_1_header','Option 2'),(190062,6961,'_content_blocks_9_images_1_header','field_6170d8f49800f'),(190063,6961,'content_blocks_9_images_1_description','Air-Over-Oil cooler'),(190064,6961,'_content_blocks_9_images_1_description','field_6170d90398010'),(190065,6961,'content_blocks_9_images_2_image',''),(190066,6961,'_content_blocks_9_images_2_image','field_6170d8e99800e'),(190067,6961,'content_blocks_9_images_2_header','Option 3'),(190068,6961,'_content_blocks_9_images_2_header','field_6170d8f49800f'),(190069,6961,'content_blocks_9_images_2_description','Chiller and heat exchanger. Water for heat exchanger re-circulates; used water from cutting runs to drain.'),(190070,6961,'_content_blocks_9_images_2_description','field_6170d90398010'),(190071,6961,'content_blocks_9_images_3_image','4134'),(190072,6961,'_content_blocks_9_images_3_image','field_6170d8e99800e'),(190073,6961,'content_blocks_9_images_3_header','Option 4'),(190074,6961,'_content_blocks_9_images_3_header','field_6170d8f49800f'),(190075,6961,'content_blocks_9_images_3_description','Heat exchanger, chiller and WRS-3000 water recycling unit. No water to drain. Only water required is make-up water to replace evaporation and spillage.'),(190076,6961,'_content_blocks_9_images_3_description','field_6170d90398010'),(190077,6961,'content_blocks_9_images','4'),(190078,6961,'_content_blocks_9_images','field_6170d8df9800d'),(190079,6961,'content_blocks_10_header','Recommendation for Water Treatment'),(190080,6961,'_content_blocks_10_header','field_6170d8ba9800b'),(190081,6961,'content_blocks_10_description','WARDJet has found that the use of a good quality water softener in conjunction with a 0.2 absolute final filter to be successful for treatment of water for the intensifier. This setup can be used as long as the water from the cutting tank is not being recycled for use through the intensifier. In the worst case, if seal life does not seem to be living up to expectations, then a DI or RO system can be installed.'),(190082,6961,'_content_blocks_10_description','field_6170d8cd9800c'),(190083,6961,'content_blocks_10_images',''),(190084,6961,'_content_blocks_10_images','field_6170d8df9800d'),(190085,4144,'_wpml_media_has_media','1'),(190086,2950,'_wp_attachment_image_alt','Waterjet University_Nozzle n Orifice Q1 Seperation Cut'),(190087,2951,'_wp_attachment_image_alt','Waterjet University_Nozzle n Orifice Q2 Through'),(190088,2952,'_wp_attachment_image_alt','Waterjet University_Nozzle n Orifice Q3 Clean Finish'),(190089,2953,'_wp_attachment_image_alt','Waterjet University_Nozzle n Orifice Q4 Good Finish'),(190090,2954,'_wp_attachment_image_alt','Waterjet University_Nozzle n Orifice Q5 Excellent Finish'),(190091,6962,'hero_gallery',''),(190092,6962,'_hero_gallery','field_60c23d554e4a3'),(190093,6962,'hero_banner','6932'),(190094,6962,'_hero_banner','field_6170dbe179470'),(190095,6962,'page_title','Precision and Quality'),(190096,6962,'_page_title','field_6170d88998008'),(190097,6962,'page_description',''),(190098,6962,'_page_description','field_6170d89398009'),(190099,6962,'content_blocks_0_header','Overview'),(190100,6962,'_content_blocks_0_header','field_6170d8ba9800b'),(190101,6962,'content_blocks_0_description','For successful abrasive waterjet cutting, there are several factors at the cutting head that determine the precision and quality of the waterjet stream and will affect the quality of part you are able to cut with an abrasive waterjet. There are other factors that will go into cutting a precise and accurate part (machine design, controls, software and high-pressure pump) that will be discussed in other chapters. This chapter will focus on the cutting head and the waterjet as it interacts with the work piece.'),(190102,6962,'_content_blocks_0_description','field_6170d8cd9800c'),(190103,6962,'content_blocks_0_images',''),(190104,6962,'_content_blocks_0_images','field_6170d8df9800d'),(190105,6962,'content_blocks_1_header','Factors affecting precision & quality'),(190106,6962,'_content_blocks_1_header','field_6170d8ba9800b'),(190107,6962,'content_blocks_1_description','Figure 1 - Abrasive and Water Only Waterjet Cutting Heads'),(190108,6962,'_content_blocks_1_description','field_6170d8cd9800c'),(190109,6962,'content_blocks_1_images_0_image','2830'),(190110,6962,'_content_blocks_1_images_0_image','field_6170d8e99800e'),(190111,6962,'content_blocks_1_images_0_header',''),(190112,6962,'_content_blocks_1_images_0_header','field_6170d8f49800f'),(190113,6962,'content_blocks_1_images_0_description',''),(190114,6962,'_content_blocks_1_images_0_description','field_6170d90398010'),(190115,6962,'content_blocks_1_images_1_image','2831'),(190116,6962,'_content_blocks_1_images_1_image','field_6170d8e99800e'),(190117,6962,'content_blocks_1_images_1_header',''),(190118,6962,'_content_blocks_1_images_1_header','field_6170d8f49800f'),(190119,6962,'content_blocks_1_images_1_description',''),(190120,6962,'_content_blocks_1_images_1_description','field_6170d90398010'),(190121,6962,'content_blocks_1_images','2'),(190122,6962,'_content_blocks_1_images','field_6170d8df9800d'),(190123,6962,'content_blocks_2_header','1 - Abrasive mixing tube length'),(190124,6962,'_content_blocks_2_header','field_6170d8ba9800b'),(190125,6962,'content_blocks_2_description','A longer abrasive mixing tube (a.k.a. abrasive nozzle) produces a more coherent waterjet stream. The optimum mixing tube length is 3\" - 4\" (75 mm - 100 mm).'),(190126,6962,'_content_blocks_2_description','field_6170d8cd9800c'),(190127,6962,'content_blocks_2_images',''),(190128,6962,'_content_blocks_2_images','field_6170d8df9800d'),(190129,6962,'content_blocks_3_header','2 - Alignment of components'),(190130,6962,'_content_blocks_3_header','field_6170d8ba9800b'),(190131,6962,'content_blocks_3_description','The orifice, mixing chamber and abrasive nozzle must be precisely machined and fit perfectly together to avoid damage of consumables by the waterjet stream.'),(190132,6962,'_content_blocks_3_description','field_6170d8cd9800c'),(190133,6962,'content_blocks_3_images',''),(190134,6962,'_content_blocks_3_images','field_6170d8df9800d'),(190135,6962,'content_blocks_4_header','3 - Precise orifice'),(190136,6962,'_content_blocks_4_header','field_6170d8ba9800b'),(190137,6962,'content_blocks_4_description','The inside of the abrasive nozzle must be machined to ensure perfect alignment with the waterjet stream. See \"Waterjet stream\'s effect on accuracy\" section of this chapter for more information.'),(190138,6962,'_content_blocks_4_description','field_6170d8cd9800c'),(190139,6962,'content_blocks_4_images',''),(190140,6962,'_content_blocks_4_images','field_6170d8df9800d'),(190141,6962,'content_blocks_5_header','4 - Diameter of stream'),(190142,6962,'_content_blocks_5_header','field_6170d8ba9800b'),(190143,6962,'content_blocks_5_description','A small diameter waterjet stream, as produced by a .010\" (0.25 mm) orifice produces an efficient, high-quality stream. As a trade-off, cutting speeds are slower than when using a 0.014\" (0.36 mm) or larger orifice, since less water and abrasive are used. See Chapter 2 \"Relationship Parameters\" for more information on orifice selection.'),(190144,6962,'_content_blocks_5_description','field_6170d8cd9800c'),(190145,6962,'content_blocks_5_images',''),(190146,6962,'_content_blocks_5_images','field_6170d8df9800d'),(190147,6962,'content_blocks_6_header','5 - Low, controlled stand-off from work'),(190148,6962,'_content_blocks_6_header','field_6170d8ba9800b'),(190149,6962,'content_blocks_6_description','Maintaining a close distance between the nozzle and the work piece, between 0.040\" and 0.060\" (1.0 - 1.5 mm), is critical for producing accurate parts while also getting the maximum efficiency from the waterjet. Cutting closer to the material limits the amount of atmosphere that the jet has to travel through before reaching the work piece. This limits the expansion of the waterjet stream, since as the jet expands, the effective power of the jet is reduced. Cutting speeds will need to be reduced to compensate. If the distance between the nozzle and the work piece is increased by ¼\", cutting speeds must be reduced by approximately 20% to achieve similar results with respect to tolerance and edge quality. Cutting under water with CNC height control will allow for ultimate control of the waterjet stream.\r\n\r\nSee effect of nozzle height below for more information.'),(190150,6962,'_content_blocks_6_description','field_6170d8cd9800c'),(190151,6962,'content_blocks_6_images',''),(190152,6962,'_content_blocks_6_images','field_6170d8df9800d'),(190153,6962,'content_blocks_7_header','Creation of the abrasive waterjet stream'),(190154,6962,'_content_blocks_7_header','field_6170d8ba9800b'),(190155,6962,'content_blocks_7_description','Following is a description of how the abrasive waterjet stream is created in the cutting head. The numbers indicated below refer to the numbers in Figure 2.'),(190156,6962,'_content_blocks_7_description','field_6170d8cd9800c'),(190157,6962,'content_blocks_7_images_0_image','2831'),(190158,6962,'_content_blocks_7_images_0_image','field_6170d8e99800e'),(190159,6962,'content_blocks_7_images_0_header',''),(190160,6962,'_content_blocks_7_images_0_header','field_6170d8f49800f'),(190161,6962,'content_blocks_7_images_0_description',''),(190162,6962,'_content_blocks_7_images_0_description','field_6170d90398010'),(190163,6962,'content_blocks_7_images','1'),(190164,6962,'_content_blocks_7_images','field_6170d8df9800d'),(190165,6962,'content_blocks_8_header','1 - Water Pressure'),(190166,6962,'_content_blocks_8_header','field_6170d8ba9800b'),(190167,6962,'content_blocks_8_description','Water pressurized at 50,000 psi or greater enters the cutting head at relatively slow speed, in the order of a few feet per second. (See \"How It Works\" for more information on how this water pressure is created and transmitted to the cutting head.)'),(190168,6962,'_content_blocks_8_description','field_6170d8cd9800c'),(190169,6962,'content_blocks_8_images',''),(190170,6962,'_content_blocks_8_images','field_6170d8df9800d'),(190171,6962,'content_blocks_9_header','Stream Conversion'),(190172,6962,'_content_blocks_9_header','field_6170d8ba9800b'),(190173,6962,'content_blocks_9_description','The water is forced through an orifice that has a small diameter orifice, anywhere from 0.004\" to 0.045\" depending upon the application. These orifices are made of extremely hard material, such as diamond, sapphire or ruby. This step converts the water stream from a high pressure stream to a high velocity stream. At this point the water is moving in excess of 2200 miles per hour (3657 kilometers per hour).'),(190174,6962,'_content_blocks_9_description','field_6170d8cd9800c'),(190175,6962,'content_blocks_9_images',''),(190176,6962,'_content_blocks_9_images','field_6170d8df9800d'),(190177,6962,'content_blocks_10_header','3 - Venturi Effect'),(190178,6962,'_content_blocks_10_header','field_6170d8ba9800b'),(190179,6962,'content_blocks_10_description','The high velocity of the jet creates a Venturi effect, or vacuum, in the mixing chamber located immediately beneath the orifice. Abrasive, typically garnet, is metered from a mini-hopper through a plastic tube down to the cutting head and is sucked into the waterjet stream in the mixing chamber. Cutting speed will increase with more abrasive until a saturation point is reached where speed starts to decrease. If the abrasive amount is increased too high, ultimately the mixing tube will clog.\r\nOne of the exciting advancements in waterjet cutting in the past few years is the appearance on CNC- controlled abrasive metering systems. These systems precisely control the amount of abrasive that is allowed to flow to the cutting head. During the piercing process, cutting pressure and abrasive amount are reduced and the cutting head makes small, circular motions in the X and Y axes. This piercing procedure allows for difficult applications, such as piercing of glass and stone, to be processed with relative ease.'),(190180,6962,'_content_blocks_10_description','field_6170d8cd9800c'),(190181,6962,'content_blocks_10_images',''),(190182,6962,'_content_blocks_10_images','field_6170d8df9800d'),(190183,6962,'content_blocks_11_header','4 - Waterjet stream & abrasive mixture'),(190184,6962,'_content_blocks_11_header','field_6170d8ba9800b'),(190185,6962,'content_blocks_11_description','The abrasive is fully mixed in the waterjet stream and is accelerated to approximately the speed of the waterjet stream. This step does steal some energy from the waterjet stream, slowing it down slightly.'),(190186,6962,'_content_blocks_11_description','field_6170d8cd9800c'),(190187,6962,'content_blocks_11_images',''),(190188,6962,'_content_blocks_11_images','field_6170d8df9800d'),(190189,6962,'content_blocks_12_header','5 - Accelerated Erosion'),(190190,6962,'_content_blocks_12_header','field_6170d8ba9800b'),(190191,6962,'content_blocks_12_description','The abrasive waterjet stream exits the mixing tube with extreme speed and power. The abrasive erodes the material to be cut. The process is referred to as \"abrasive waterjet cutting\" because it is the abrasive that is actually doing the cutting. The water\'s role is simply to give speed and power to the abrasive. In pure waterjet cutting, used for soft materials like foam and food, the force of the waterjet stream alone is enough to cut the material and abrasive is not required.'),(190192,6962,'_content_blocks_12_description','field_6170d8cd9800c'),(190193,6962,'content_blocks_12_images',''),(190194,6962,'_content_blocks_12_images','field_6170d8df9800d'),(190195,6962,'content_blocks_13_header','Affect of speed upon kerf angle'),(190196,6962,'_content_blocks_13_header','field_6170d8ba9800b'),(190197,6962,'content_blocks_13_description','Kerf angle, or bevel, refers to the dimensional difference between the top and bottom of the cut cross-section. Cutting too fast will result in a wider kerf width at the top of the cut cross-section and a narrower kerf width at the bottom of the zone. In Fig. 3, from left to right, cuts were done at 26 inches per minute (ipm), 14 ipm and 9.7 ipm (660 millimeters per minute [mm/min], 355 mm/min and 246 mm/min). All other parameters were held constant (pressure 60 kpsi, 0.060\" standoff distance, 1.3 lb/min abrasive [4134 bar, 1.5mm and 600 grams/min]). At the top of the cut, kerf width was similar, around 0.044\" (1.12 mm). The difference between top and bottom going from left to right was 0.017\", 0.013\" and 0.011\" (0.43 mm, 0.33 mm and 0.28 mm). This shows the decrease in angularity as speed decreases.\r\n\r\nFigure 3 - 3/4\" (20 mm) Aluminum with 3 different cut speeds'),(190198,6962,'_content_blocks_13_description','field_6170d8cd9800c'),(190199,6962,'content_blocks_13_images_0_image','2832'),(190200,6962,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(190201,6962,'content_blocks_13_images_0_header','High Speed, Widest Kerf at Top, Narrowest aat Bottom'),(190202,6962,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(190203,6962,'content_blocks_13_images_0_description',''),(190204,6962,'_content_blocks_13_images_0_description','field_6170d90398010'),(190205,6962,'content_blocks_13_images_1_image','2833'),(190206,6962,'_content_blocks_13_images_1_image','field_6170d8e99800e'),(190207,6962,'content_blocks_13_images_1_header','Medium Speed, Wider Kerf width at top than at bottom'),(190208,6962,'_content_blocks_13_images_1_header','field_6170d8f49800f'),(190209,6962,'content_blocks_13_images_1_description',''),(190210,6962,'_content_blocks_13_images_1_description','field_6170d90398010'),(190211,6962,'content_blocks_13_images_2_image','2834'),(190212,6962,'_content_blocks_13_images_2_image','field_6170d8e99800e'),(190213,6962,'content_blocks_13_images_2_header','Slower Speed, Similar width Kerf at top and bottom'),(190214,6962,'_content_blocks_13_images_2_header','field_6170d8f49800f'),(190215,6962,'content_blocks_13_images_2_description',''),(190216,6962,'_content_blocks_13_images_2_description','field_6170d90398010'),(190217,6962,'content_blocks_13_images','3'),(190218,6962,'_content_blocks_13_images','field_6170d8df9800d'),(190219,6962,'content_blocks_14_header',''),(190220,6962,'_content_blocks_14_header','field_6170d8ba9800b'),(190221,6962,'content_blocks_14_description','The picture below shows one additional cut that was done extremely slowly (1 ipm or 25.4 mm/min) to demonstrate that when speed is decreased enough, the kerf width at the bottom of the part will be larger than at the top. In this example the kerf width at the bottom was 0.014\" (0.36 mm) larger than at the top.'),(190222,6962,'_content_blocks_14_description','field_6170d8cd9800c'),(190223,6962,'content_blocks_14_images_0_image','2835'),(190224,6962,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(190225,6962,'content_blocks_14_images_0_header','Very slow speed, Narrower kerf width at top, Wider at Bottom'),(190226,6962,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(190227,6962,'content_blocks_14_images_0_description',''),(190228,6962,'_content_blocks_14_images_0_description','field_6170d90398010'),(190229,6962,'content_blocks_14_images','1'),(190230,6962,'_content_blocks_14_images','field_6170d8df9800d'),(190231,6962,'content_blocks','22'),(190232,6962,'_content_blocks','field_6170d8ac9800a'),(190233,6962,'menu','37'),(190234,6962,'_menu','field_6170d9e059837'),(190235,6962,'display_left_column','1'),(190236,6962,'_display_left_column','field_613563c4d424b'),(190237,6962,'contact_left_heading',''),(190238,6962,'_contact_left_heading','field_60c249d645c99'),(190239,6962,'contact_left_copy',''),(190240,6962,'_contact_left_copy','field_60c24a0845c9c'),(190241,6962,'display_right_column','1'),(190242,6962,'_display_right_column','field_613563f4d424c'),(190243,6962,'contact_right_heading',''),(190244,6962,'_contact_right_heading','field_60c249e945c9a'),(190245,6962,'contact_right_copy',''),(190246,6962,'_contact_right_copy','field_60c249f845c9b'),(190247,6962,'contact_right_cta',''),(190248,6962,'_contact_right_cta','field_60c24a1945c9d'),(190249,6962,'content_blocks_15_header','Drag of waterjet stream and cut quality'),(190250,6962,'_content_blocks_15_header','field_6170d8ba9800b'),(190251,6962,'content_blocks_15_description','Increasing feedrate results in increased trail back of waterjet stream. This concept is shown in Figure 5 below. Rougher edge quality is the result of more shearing action versus erosion action of abrasive at slower speeds. Modern controllers allow the user to adjust cut quality based upon part requirements. High-precision holes can be cut slower for a smoother, straighter cut. Faster cutting speeds with rougher edge quality can be used on less critical areas.'),(190252,6962,'_content_blocks_15_description','field_6170d8cd9800c'),(190253,6962,'content_blocks_15_images_0_image','2950'),(190254,6962,'_content_blocks_15_images_0_image','field_6170d8e99800e'),(190255,6962,'content_blocks_15_images_0_header','Seperation Cut'),(190256,6962,'_content_blocks_15_images_0_header','field_6170d8f49800f'),(190257,6962,'content_blocks_15_images_0_description',''),(190258,6962,'_content_blocks_15_images_0_description','field_6170d90398010'),(190259,6962,'content_blocks_15_images_1_image','2951'),(190260,6962,'_content_blocks_15_images_1_image','field_6170d8e99800e'),(190261,6962,'content_blocks_15_images_1_header','Through Cut'),(190262,6962,'_content_blocks_15_images_1_header','field_6170d8f49800f'),(190263,6962,'content_blocks_15_images_1_description',''),(190264,6962,'_content_blocks_15_images_1_description','field_6170d90398010'),(190265,6962,'content_blocks_15_images_2_image','2952'),(190266,6962,'_content_blocks_15_images_2_image','field_6170d8e99800e'),(190267,6962,'content_blocks_15_images_2_header','Clean Cut ± 0.010\"'),(190268,6962,'_content_blocks_15_images_2_header','field_6170d8f49800f'),(190269,6962,'content_blocks_15_images_2_description',''),(190270,6962,'_content_blocks_15_images_2_description','field_6170d90398010'),(190271,6962,'content_blocks_15_images_3_image','2953'),(190272,6962,'_content_blocks_15_images_3_image','field_6170d8e99800e'),(190273,6962,'content_blocks_15_images_3_header','Good Finish'),(190274,6962,'_content_blocks_15_images_3_header','field_6170d8f49800f'),(190275,6962,'content_blocks_15_images_3_description',''),(190276,6962,'_content_blocks_15_images_3_description','field_6170d90398010'),(190277,6962,'content_blocks_15_images_4_image','2954'),(190278,6962,'_content_blocks_15_images_4_image','field_6170d8e99800e'),(190279,6962,'content_blocks_15_images_4_header','Excellent Finish ± 0.005\"'),(190280,6962,'_content_blocks_15_images_4_header','field_6170d8f49800f'),(190281,6962,'content_blocks_15_images_4_description',''),(190282,6962,'_content_blocks_15_images_4_description','field_6170d90398010'),(190283,6962,'content_blocks_15_images','5'),(190284,6962,'_content_blocks_15_images','field_6170d8df9800d'),(190285,6962,'content_blocks_16_header','Effect of Nozzle Height'),(190286,6962,'_content_blocks_16_header','field_6170d8ba9800b'),(190287,6962,'content_blocks_16_description','For best cut quality, an optimum distance between the nozzle and the work piece should be maintained. Typically, between 0.0625\" and 0.125\" (1.5 – 3.0 mm) is the optimum height for abrasive waterjet cutting. As the distance increases above 0.125\", rounding on the top edge of the cut will result. This occurs because the waterjet stream looses coherence as it travels through open air. Increased nozzle height will also result in increased kerf angle. If the distance between the nozzle and the work piece is increased by ¼\", cutting speeds must be reduced by approximately 20% to achieve similar results with respect to tolerance and edge quality. Automatic height control is the most reliable and accurate way to maintain proper standoff distance. Figure 7 shows that if the nozzle height is increased too far, the jet will not have enough power to fully penetrate material that it would easily cut at much lower heights.'),(190288,6962,'_content_blocks_16_description','field_6170d8cd9800c'),(190289,6962,'content_blocks_16_images_0_image','2838'),(190290,6962,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(190291,6962,'content_blocks_16_images_0_header',''),(190292,6962,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(190293,6962,'content_blocks_16_images_0_description','Figure 6 - 3/4\" Aluminum with cuts at various nozzle heights, same speed'),(190294,6962,'_content_blocks_16_images_0_description','field_6170d90398010'),(190295,6962,'content_blocks_16_images_1_image','2839'),(190296,6962,'_content_blocks_16_images_1_image','field_6170d8e99800e'),(190297,6962,'content_blocks_16_images_1_header',''),(190298,6962,'_content_blocks_16_images_1_header','field_6170d8f49800f'),(190299,6962,'content_blocks_16_images_1_description','Figure 7 - Increasing nozzle height to point of no jet penetration'),(190300,6962,'_content_blocks_16_images_1_description','field_6170d90398010'),(190301,6962,'content_blocks_16_images','2'),(190302,6962,'_content_blocks_16_images','field_6170d8df9800d'),(190303,6962,'content_blocks_17_header','Effect of speed on inside corners'),(190304,6962,'_content_blocks_17_header','field_6170d8ba9800b'),(190305,6962,'content_blocks_17_description','Since the waterjet is a non-rigid cutting tool, inside corners on parts can exhibit a certain amount of overcut on the bottom, or exit, side of the part. This can be reduced by decelerating into the corner and slowly accelerating, allowing the bottom portion of the jet to catch up with the top portion around the corner. The waterjet control must have the ability to do this automatically.'),(190306,6962,'_content_blocks_17_description','field_6170d8cd9800c'),(190307,6962,'content_blocks_17_images_0_image',''),(190308,6962,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(190309,6962,'content_blocks_17_images_0_header','missing Images'),(190310,6962,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(190311,6962,'content_blocks_17_images_0_description',''),(190312,6962,'_content_blocks_17_images_0_description','field_6170d90398010'),(190313,6962,'content_blocks_17_images','1'),(190314,6962,'_content_blocks_17_images','field_6170d8df9800d'),(190315,6962,'content_blocks_18_header','Tight radii'),(190316,6962,'_content_blocks_18_header','field_6170d8ba9800b'),(190317,6962,'content_blocks_18_description','Since the waterjet stream is a round tool, with a diameter between 0.030\" and 0.040\" (0.76 mm and 1.02 mm) for abrasive waterjet cutting, creating any inside corner that is perfectly square is impossible. CAM software will typically read geometries and give a user the option to automatically place a very small radius on these corners. This will avoid damaging the part and reduce processing time, as radii are faster to cut than square corners. For very acute angles, the actual part that is cut may differ significantly from the original drawing and should be considered for form, fit and function before processing.'),(190318,6962,'_content_blocks_18_description','field_6170d8cd9800c'),(190319,6962,'content_blocks_18_images_0_image','2840'),(190320,6962,'_content_blocks_18_images_0_image','field_6170d8e99800e'),(190321,6962,'content_blocks_18_images_0_header',''),(190322,6962,'_content_blocks_18_images_0_header','field_6170d8f49800f'),(190323,6962,'content_blocks_18_images_0_description',''),(190324,6962,'_content_blocks_18_images_0_description','field_6170d90398010'),(190325,6962,'content_blocks_18_images','1'),(190326,6962,'_content_blocks_18_images','field_6170d8df9800d'),(190327,6962,'content_blocks_19_header','Lead-in and Lead-out types'),(190328,6962,'_content_blocks_19_header','field_6170d8ba9800b'),(190329,6962,'content_blocks_19_description','Piercing in the scrap area of material and \"leading-in\" to the actual geometry to cut is standard operating procedure in most waterjet applications. This avoids placing a large blow-out blemish from the initial piercing on the surface of the part. At the end of a cut, a lead-out may be required to remove any \"nib\" from the lead-in area.\r\n\r\nVarious types of lead-ins and lead-outs can be experimented with for different materials and thicknesses. Figure 9 shows a few examples of lead-ins and leads-outs.'),(190330,6962,'_content_blocks_19_description','field_6170d8cd9800c'),(190331,6962,'content_blocks_19_images_0_image','2842'),(190332,6962,'_content_blocks_19_images_0_image','field_6170d8e99800e'),(190333,6962,'content_blocks_19_images_0_header','Different lead-in/lead-out types'),(190334,6962,'_content_blocks_19_images_0_header','field_6170d8f49800f'),(190335,6962,'content_blocks_19_images_0_description','Number 1 (straight line lead-in with very short straight line lead-out) is desirable for any sharp corner.\r\n\r\nNumber 2 (arc lead-in with short arc lead-out) is good for thinner and softer materials.\r\n\r\nNumber 3 (straight line lead in with no lead-out) gives good results on thicker, harder material.\r\n\r\nNumber 4 is an example of a straight line lead in with short arc lead-out. CAM software should have the flexibility to combine different types of lead-ins and lead-outs should the user wish to experiment.'),(190336,6962,'_content_blocks_19_images_0_description','field_6170d90398010'),(190337,6962,'content_blocks_19_images','1'),(190338,6962,'_content_blocks_19_images','field_6170d8df9800d'),(190339,6962,'content_blocks_20_header','Reducing lead-in/lead-out witness marks'),(190340,6962,'_content_blocks_20_header','field_6170d8ba9800b'),(190341,6962,'content_blocks_20_description','At the end of a cut, a small nib may remain on the bottom portion of the cut in the lead-in/lead-out area. Because of the lagging effect discussed previously, when the jet reaches the end of the cut, the top portion of the jet will find the path of least resistance, and effectively \"jump over\" a small bit of material leaving a nib. With the more sophisticated controls and software available today, this can be reduced by decelerating at the end of the cut to allow the bottom portion of the jet to catch up with the top before reaching the end of the cut. Figure 10 below shows examples of a large nib because of too much speed at the end of a cut and an example of a minimal witness mark with appropriate slow down at the end of the cut.'),(190342,6962,'_content_blocks_20_description','field_6170d8cd9800c'),(190343,6962,'content_blocks_20_images_0_image','2843'),(190344,6962,'_content_blocks_20_images_0_image','field_6170d8e99800e'),(190345,6962,'content_blocks_20_images_0_header','Bad part on left showing excessive nib.'),(190346,6962,'_content_blocks_20_images_0_header','field_6170d8f49800f'),(190347,6962,'content_blocks_20_images_0_description',''),(190348,6962,'_content_blocks_20_images_0_description','field_6170d90398010'),(190349,6962,'content_blocks_20_images_1_image','2844'),(190350,6962,'_content_blocks_20_images_1_image','field_6170d8e99800e'),(190351,6962,'content_blocks_20_images_1_header','Good part on right with minimal witness mark'),(190352,6962,'_content_blocks_20_images_1_header','field_6170d8f49800f'),(190353,6962,'content_blocks_20_images_1_description',''),(190354,6962,'_content_blocks_20_images_1_description','field_6170d90398010'),(190355,6962,'content_blocks_20_images','2'),(190356,6962,'_content_blocks_20_images','field_6170d8df9800d'),(190357,6962,'content_blocks_21_header','Waterjet stream\'s effect on accuracy'),(190358,6962,'_content_blocks_21_header','field_6170d8ba9800b'),(190359,6962,'content_blocks_21_description','Mixing tubes are made of extremely hard materials such as sintered boride or more commonly composite tungsten carbide. However, the nozzles are subject to wear and their cost must be taken into consideration for job costing. The orifice of a mixing tube will typically increase in diameter by about 0.0001\" per hour of cutting because of the erosion of the abrasive flowing through the nozzle. If this wear occurs in an even fashion, up to 120 hours of cutting can be realized with a nozzle. The biggest factor affecting nozzle wear is the material from which they are made. Controls allow for compensating for this wear by allowing the operator to change the tool offset.\r\n\r\nIf the wear of the nozzle is not symmetrical, the waterjet stream will also not be round. This will result in wider tolerances when cutting in a certain direction.\r\n\r\nThe tolerance requirements of a job will dictate the actual number of hours a user can expect from a nozzle. The nozzle can, of course, be set aside and used later for looser tolerance jobs. Control software should allow the ability to track hours on individual components to make consumable management easier. See Figure 12 below for an example of orifice and mixing tube tracking.'),(190360,6962,'_content_blocks_21_description','field_6170d8cd9800c'),(190361,6962,'content_blocks_21_images_0_image',''),(190362,6962,'_content_blocks_21_images_0_image','field_6170d8e99800e'),(190363,6962,'content_blocks_21_images_0_header','Need Image'),(190364,6962,'_content_blocks_21_images_0_header','field_6170d8f49800f'),(190365,6962,'content_blocks_21_images_0_description',''),(190366,6962,'_content_blocks_21_images_0_description','field_6170d90398010'),(190367,6962,'content_blocks_21_images_1_image','2845'),(190368,6962,'_content_blocks_21_images_1_image','field_6170d8e99800e'),(190369,6962,'content_blocks_21_images_1_header','Orifice on right is off-center.'),(190370,6962,'_content_blocks_21_images_1_header','field_6170d8f49800f'),(190371,6962,'content_blocks_21_images_1_description',''),(190372,6962,'_content_blocks_21_images_1_description','field_6170d90398010'),(190373,6962,'content_blocks_21_images','2'),(190374,6962,'_content_blocks_21_images','field_6170d8df9800d'),(190376,3569,'content_blocks_15_images_0_image','2950'),(190377,3569,'content_blocks_15_images_1_image','2951'),(190378,3569,'content_blocks_15_images_2_image','2952'),(190379,3569,'content_blocks_15_images_3_image','2953'),(190380,3569,'content_blocks_15_images_4_image','2954'),(190381,3468,'content_blocks_15_images_0_image','2950'),(190382,3468,'content_blocks_15_images_1_image','2951'),(190383,3468,'content_blocks_15_images_2_image','2952'),(190384,3468,'content_blocks_15_images_3_image','2953'),(190385,3468,'content_blocks_15_images_4_image','2954'),(190386,6963,'_wp_attached_file','2022/03/Effect-of-speed-on-inside-corners.jpg'),(190387,6963,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:600;s:6:\"height\";i:290;s:4:\"file\";s:45:\"2022/03/Effect-of-speed-on-inside-corners.jpg\";s:5:\"sizes\";a:2:{s:6:\"medium\";a:4:{s:4:\"file\";s:45:\"Effect-of-speed-on-inside-corners-300x145.jpg\";s:5:\"width\";i:300;s:6:\"height\";i:145;s:9:\"mime-type\";s:10:\"image/jpeg\";}s:9:\"thumbnail\";a:4:{s:4:\"file\";s:45:\"Effect-of-speed-on-inside-corners-150x150.jpg\";s:5:\"width\";i:150;s:6:\"height\";i:150;s:9:\"mime-type\";s:10:\"image/jpeg\";}}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(190388,6963,'_wp_attachment_image_alt','Effect of speed on inside corners'),(190389,6963,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2829;}}'),(190390,6964,'hero_gallery',''),(190391,6964,'_hero_gallery','field_60c23d554e4a3'),(190392,6964,'hero_banner','6932'),(190393,6964,'_hero_banner','field_6170dbe179470'),(190394,6964,'page_title','Precision and Quality'),(190395,6964,'_page_title','field_6170d88998008'),(190396,6964,'page_description',''),(190397,6964,'_page_description','field_6170d89398009'),(190398,6964,'content_blocks_0_header','Overview'),(190399,6964,'_content_blocks_0_header','field_6170d8ba9800b'),(190400,6964,'content_blocks_0_description','For successful abrasive waterjet cutting, there are several factors at the cutting head that determine the precision and quality of the waterjet stream and will affect the quality of part you are able to cut with an abrasive waterjet. There are other factors that will go into cutting a precise and accurate part (machine design, controls, software and high-pressure pump) that will be discussed in other chapters. This chapter will focus on the cutting head and the waterjet as it interacts with the work piece.'),(190401,6964,'_content_blocks_0_description','field_6170d8cd9800c'),(190402,6964,'content_blocks_0_images',''),(190403,6964,'_content_blocks_0_images','field_6170d8df9800d'),(190404,6964,'content_blocks_1_header','Factors affecting precision & quality'),(190405,6964,'_content_blocks_1_header','field_6170d8ba9800b'),(190406,6964,'content_blocks_1_description','Figure 1 - Abrasive and Water Only Waterjet Cutting Heads'),(190407,6964,'_content_blocks_1_description','field_6170d8cd9800c'),(190408,6964,'content_blocks_1_images_0_image','2830'),(190409,6964,'_content_blocks_1_images_0_image','field_6170d8e99800e'),(190410,6964,'content_blocks_1_images_0_header',''),(190411,6964,'_content_blocks_1_images_0_header','field_6170d8f49800f'),(190412,6964,'content_blocks_1_images_0_description',''),(190413,6964,'_content_blocks_1_images_0_description','field_6170d90398010'),(190414,6964,'content_blocks_1_images_1_image','2831'),(190415,6964,'_content_blocks_1_images_1_image','field_6170d8e99800e'),(190416,6964,'content_blocks_1_images_1_header',''),(190417,6964,'_content_blocks_1_images_1_header','field_6170d8f49800f'),(190418,6964,'content_blocks_1_images_1_description',''),(190419,6964,'_content_blocks_1_images_1_description','field_6170d90398010'),(190420,6964,'content_blocks_1_images','2'),(190421,6964,'_content_blocks_1_images','field_6170d8df9800d'),(190422,6964,'content_blocks_2_header','1 - Abrasive mixing tube length'),(190423,6964,'_content_blocks_2_header','field_6170d8ba9800b'),(190424,6964,'content_blocks_2_description','A longer abrasive mixing tube (a.k.a. abrasive nozzle) produces a more coherent waterjet stream. The optimum mixing tube length is 3\" - 4\" (75 mm - 100 mm).'),(190425,6964,'_content_blocks_2_description','field_6170d8cd9800c'),(190426,6964,'content_blocks_2_images',''),(190427,6964,'_content_blocks_2_images','field_6170d8df9800d'),(190428,6964,'content_blocks_3_header','2 - Alignment of components'),(190429,6964,'_content_blocks_3_header','field_6170d8ba9800b'),(190430,6964,'content_blocks_3_description','The orifice, mixing chamber and abrasive nozzle must be precisely machined and fit perfectly together to avoid damage of consumables by the waterjet stream.'),(190431,6964,'_content_blocks_3_description','field_6170d8cd9800c'),(190432,6964,'content_blocks_3_images',''),(190433,6964,'_content_blocks_3_images','field_6170d8df9800d'),(190434,6964,'content_blocks_4_header','3 - Precise orifice'),(190435,6964,'_content_blocks_4_header','field_6170d8ba9800b'),(190436,6964,'content_blocks_4_description','The inside of the abrasive nozzle must be machined to ensure perfect alignment with the waterjet stream. See \"Waterjet stream\'s effect on accuracy\" section of this chapter for more information.'),(190437,6964,'_content_blocks_4_description','field_6170d8cd9800c'),(190438,6964,'content_blocks_4_images',''),(190439,6964,'_content_blocks_4_images','field_6170d8df9800d'),(190440,6964,'content_blocks_5_header','4 - Diameter of stream'),(190441,6964,'_content_blocks_5_header','field_6170d8ba9800b'),(190442,6964,'content_blocks_5_description','A small diameter waterjet stream, as produced by a .010\" (0.25 mm) orifice produces an efficient, high-quality stream. As a trade-off, cutting speeds are slower than when using a 0.014\" (0.36 mm) or larger orifice, since less water and abrasive are used. See Chapter 2 \"Relationship Parameters\" for more information on orifice selection.'),(190443,6964,'_content_blocks_5_description','field_6170d8cd9800c'),(190444,6964,'content_blocks_5_images',''),(190445,6964,'_content_blocks_5_images','field_6170d8df9800d'),(190446,6964,'content_blocks_6_header','5 - Low, controlled stand-off from work'),(190447,6964,'_content_blocks_6_header','field_6170d8ba9800b'),(190448,6964,'content_blocks_6_description','Maintaining a close distance between the nozzle and the work piece, between 0.040\" and 0.060\" (1.0 - 1.5 mm), is critical for producing accurate parts while also getting the maximum efficiency from the waterjet. Cutting closer to the material limits the amount of atmosphere that the jet has to travel through before reaching the work piece. This limits the expansion of the waterjet stream, since as the jet expands, the effective power of the jet is reduced. Cutting speeds will need to be reduced to compensate. If the distance between the nozzle and the work piece is increased by ¼\", cutting speeds must be reduced by approximately 20% to achieve similar results with respect to tolerance and edge quality. Cutting under water with CNC height control will allow for ultimate control of the waterjet stream.\r\n\r\nSee effect of nozzle height below for more information.'),(190449,6964,'_content_blocks_6_description','field_6170d8cd9800c'),(190450,6964,'content_blocks_6_images',''),(190451,6964,'_content_blocks_6_images','field_6170d8df9800d'),(190452,6964,'content_blocks_7_header','Creation of the abrasive waterjet stream'),(190453,6964,'_content_blocks_7_header','field_6170d8ba9800b'),(190454,6964,'content_blocks_7_description','Following is a description of how the abrasive waterjet stream is created in the cutting head. The numbers indicated below refer to the numbers in Figure 2.'),(190455,6964,'_content_blocks_7_description','field_6170d8cd9800c'),(190456,6964,'content_blocks_7_images_0_image','2831'),(190457,6964,'_content_blocks_7_images_0_image','field_6170d8e99800e'),(190458,6964,'content_blocks_7_images_0_header',''),(190459,6964,'_content_blocks_7_images_0_header','field_6170d8f49800f'),(190460,6964,'content_blocks_7_images_0_description',''),(190461,6964,'_content_blocks_7_images_0_description','field_6170d90398010'),(190462,6964,'content_blocks_7_images','1'),(190463,6964,'_content_blocks_7_images','field_6170d8df9800d'),(190464,6964,'content_blocks_8_header','1 - Water Pressure'),(190465,6964,'_content_blocks_8_header','field_6170d8ba9800b'),(190466,6964,'content_blocks_8_description','Water pressurized at 50,000 psi or greater enters the cutting head at relatively slow speed, in the order of a few feet per second. (See \"How It Works\" for more information on how this water pressure is created and transmitted to the cutting head.)'),(190467,6964,'_content_blocks_8_description','field_6170d8cd9800c'),(190468,6964,'content_blocks_8_images',''),(190469,6964,'_content_blocks_8_images','field_6170d8df9800d'),(190470,6964,'content_blocks_9_header','Stream Conversion'),(190471,6964,'_content_blocks_9_header','field_6170d8ba9800b'),(190472,6964,'content_blocks_9_description','The water is forced through an orifice that has a small diameter orifice, anywhere from 0.004\" to 0.045\" depending upon the application. These orifices are made of extremely hard material, such as diamond, sapphire or ruby. This step converts the water stream from a high pressure stream to a high velocity stream. At this point the water is moving in excess of 2200 miles per hour (3657 kilometers per hour).'),(190473,6964,'_content_blocks_9_description','field_6170d8cd9800c'),(190474,6964,'content_blocks_9_images',''),(190475,6964,'_content_blocks_9_images','field_6170d8df9800d'),(190476,6964,'content_blocks_10_header','3 - Venturi Effect'),(190477,6964,'_content_blocks_10_header','field_6170d8ba9800b'),(190478,6964,'content_blocks_10_description','The high velocity of the jet creates a Venturi effect, or vacuum, in the mixing chamber located immediately beneath the orifice. Abrasive, typically garnet, is metered from a mini-hopper through a plastic tube down to the cutting head and is sucked into the waterjet stream in the mixing chamber. Cutting speed will increase with more abrasive until a saturation point is reached where speed starts to decrease. If the abrasive amount is increased too high, ultimately the mixing tube will clog.\r\nOne of the exciting advancements in waterjet cutting in the past few years is the appearance on CNC- controlled abrasive metering systems. These systems precisely control the amount of abrasive that is allowed to flow to the cutting head. During the piercing process, cutting pressure and abrasive amount are reduced and the cutting head makes small, circular motions in the X and Y axes. This piercing procedure allows for difficult applications, such as piercing of glass and stone, to be processed with relative ease.'),(190479,6964,'_content_blocks_10_description','field_6170d8cd9800c'),(190480,6964,'content_blocks_10_images',''),(190481,6964,'_content_blocks_10_images','field_6170d8df9800d'),(190482,6964,'content_blocks_11_header','4 - Waterjet stream & abrasive mixture'),(190483,6964,'_content_blocks_11_header','field_6170d8ba9800b'),(190484,6964,'content_blocks_11_description','The abrasive is fully mixed in the waterjet stream and is accelerated to approximately the speed of the waterjet stream. This step does steal some energy from the waterjet stream, slowing it down slightly.'),(190485,6964,'_content_blocks_11_description','field_6170d8cd9800c'),(190486,6964,'content_blocks_11_images',''),(190487,6964,'_content_blocks_11_images','field_6170d8df9800d'),(190488,6964,'content_blocks_12_header','5 - Accelerated Erosion'),(190489,6964,'_content_blocks_12_header','field_6170d8ba9800b'),(190490,6964,'content_blocks_12_description','The abrasive waterjet stream exits the mixing tube with extreme speed and power. The abrasive erodes the material to be cut. The process is referred to as \"abrasive waterjet cutting\" because it is the abrasive that is actually doing the cutting. The water\'s role is simply to give speed and power to the abrasive. In pure waterjet cutting, used for soft materials like foam and food, the force of the waterjet stream alone is enough to cut the material and abrasive is not required.'),(190491,6964,'_content_blocks_12_description','field_6170d8cd9800c'),(190492,6964,'content_blocks_12_images',''),(190493,6964,'_content_blocks_12_images','field_6170d8df9800d'),(190494,6964,'content_blocks_13_header','Affect of speed upon kerf angle'),(190495,6964,'_content_blocks_13_header','field_6170d8ba9800b'),(190496,6964,'content_blocks_13_description','Kerf angle, or bevel, refers to the dimensional difference between the top and bottom of the cut cross-section. Cutting too fast will result in a wider kerf width at the top of the cut cross-section and a narrower kerf width at the bottom of the zone. In Fig. 3, from left to right, cuts were done at 26 inches per minute (ipm), 14 ipm and 9.7 ipm (660 millimeters per minute [mm/min], 355 mm/min and 246 mm/min). All other parameters were held constant (pressure 60 kpsi, 0.060\" standoff distance, 1.3 lb/min abrasive [4134 bar, 1.5mm and 600 grams/min]). At the top of the cut, kerf width was similar, around 0.044\" (1.12 mm). The difference between top and bottom going from left to right was 0.017\", 0.013\" and 0.011\" (0.43 mm, 0.33 mm and 0.28 mm). This shows the decrease in angularity as speed decreases.\r\n\r\nFigure 3 - 3/4\" (20 mm) Aluminum with 3 different cut speeds'),(190497,6964,'_content_blocks_13_description','field_6170d8cd9800c'),(190498,6964,'content_blocks_13_images_0_image','2832'),(190499,6964,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(190500,6964,'content_blocks_13_images_0_header','High Speed, Widest Kerf at Top, Narrowest aat Bottom'),(190501,6964,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(190502,6964,'content_blocks_13_images_0_description',''),(190503,6964,'_content_blocks_13_images_0_description','field_6170d90398010'),(190504,6964,'content_blocks_13_images_1_image','2833'),(190505,6964,'_content_blocks_13_images_1_image','field_6170d8e99800e'),(190506,6964,'content_blocks_13_images_1_header','Medium Speed, Wider Kerf width at top than at bottom'),(190507,6964,'_content_blocks_13_images_1_header','field_6170d8f49800f'),(190508,6964,'content_blocks_13_images_1_description',''),(190509,6964,'_content_blocks_13_images_1_description','field_6170d90398010'),(190510,6964,'content_blocks_13_images_2_image','2834'),(190511,6964,'_content_blocks_13_images_2_image','field_6170d8e99800e'),(190512,6964,'content_blocks_13_images_2_header','Slower Speed, Similar width Kerf at top and bottom'),(190513,6964,'_content_blocks_13_images_2_header','field_6170d8f49800f'),(190514,6964,'content_blocks_13_images_2_description',''),(190515,6964,'_content_blocks_13_images_2_description','field_6170d90398010'),(190516,6964,'content_blocks_13_images','3'),(190517,6964,'_content_blocks_13_images','field_6170d8df9800d'),(190518,6964,'content_blocks_14_header',''),(190519,6964,'_content_blocks_14_header','field_6170d8ba9800b'),(190520,6964,'content_blocks_14_description','The picture below shows one additional cut that was done extremely slowly (1 ipm or 25.4 mm/min) to demonstrate that when speed is decreased enough, the kerf width at the bottom of the part will be larger than at the top. In this example the kerf width at the bottom was 0.014\" (0.36 mm) larger than at the top.'),(190521,6964,'_content_blocks_14_description','field_6170d8cd9800c'),(190522,6964,'content_blocks_14_images_0_image','2835'),(190523,6964,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(190524,6964,'content_blocks_14_images_0_header','Very slow speed, Narrower kerf width at top, Wider at Bottom'),(190525,6964,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(190526,6964,'content_blocks_14_images_0_description',''),(190527,6964,'_content_blocks_14_images_0_description','field_6170d90398010'),(190528,6964,'content_blocks_14_images','1'),(190529,6964,'_content_blocks_14_images','field_6170d8df9800d'),(190530,6964,'content_blocks','22'),(190531,6964,'_content_blocks','field_6170d8ac9800a'),(190532,6964,'menu','37'),(190533,6964,'_menu','field_6170d9e059837'),(190534,6964,'display_left_column','1'),(190535,6964,'_display_left_column','field_613563c4d424b'),(190536,6964,'contact_left_heading',''),(190537,6964,'_contact_left_heading','field_60c249d645c99'),(190538,6964,'contact_left_copy',''),(190539,6964,'_contact_left_copy','field_60c24a0845c9c'),(190540,6964,'display_right_column','1'),(190541,6964,'_display_right_column','field_613563f4d424c'),(190542,6964,'contact_right_heading',''),(190543,6964,'_contact_right_heading','field_60c249e945c9a'),(190544,6964,'contact_right_copy',''),(190545,6964,'_contact_right_copy','field_60c249f845c9b'),(190546,6964,'contact_right_cta',''),(190547,6964,'_contact_right_cta','field_60c24a1945c9d'),(190548,6964,'content_blocks_15_header','Drag of waterjet stream and cut quality'),(190549,6964,'_content_blocks_15_header','field_6170d8ba9800b'),(190550,6964,'content_blocks_15_description','Increasing feedrate results in increased trail back of waterjet stream. This concept is shown in Figure 5 below. Rougher edge quality is the result of more shearing action versus erosion action of abrasive at slower speeds. Modern controllers allow the user to adjust cut quality based upon part requirements. High-precision holes can be cut slower for a smoother, straighter cut. Faster cutting speeds with rougher edge quality can be used on less critical areas.'),(190551,6964,'_content_blocks_15_description','field_6170d8cd9800c'),(190552,6964,'content_blocks_15_images_0_image','2950'),(190553,6964,'_content_blocks_15_images_0_image','field_6170d8e99800e'),(190554,6964,'content_blocks_15_images_0_header','Seperation Cut'),(190555,6964,'_content_blocks_15_images_0_header','field_6170d8f49800f'),(190556,6964,'content_blocks_15_images_0_description',''),(190557,6964,'_content_blocks_15_images_0_description','field_6170d90398010'),(190558,6964,'content_blocks_15_images_1_image','2951'),(190559,6964,'_content_blocks_15_images_1_image','field_6170d8e99800e'),(190560,6964,'content_blocks_15_images_1_header','Through Cut'),(190561,6964,'_content_blocks_15_images_1_header','field_6170d8f49800f'),(190562,6964,'content_blocks_15_images_1_description',''),(190563,6964,'_content_blocks_15_images_1_description','field_6170d90398010'),(190564,6964,'content_blocks_15_images_2_image','2952'),(190565,6964,'_content_blocks_15_images_2_image','field_6170d8e99800e'),(190566,6964,'content_blocks_15_images_2_header','Clean Cut ± 0.010\"'),(190567,6964,'_content_blocks_15_images_2_header','field_6170d8f49800f'),(190568,6964,'content_blocks_15_images_2_description',''),(190569,6964,'_content_blocks_15_images_2_description','field_6170d90398010'),(190570,6964,'content_blocks_15_images_3_image','2953'),(190571,6964,'_content_blocks_15_images_3_image','field_6170d8e99800e'),(190572,6964,'content_blocks_15_images_3_header','Good Finish'),(190573,6964,'_content_blocks_15_images_3_header','field_6170d8f49800f'),(190574,6964,'content_blocks_15_images_3_description',''),(190575,6964,'_content_blocks_15_images_3_description','field_6170d90398010'),(190576,6964,'content_blocks_15_images_4_image','2954'),(190577,6964,'_content_blocks_15_images_4_image','field_6170d8e99800e'),(190578,6964,'content_blocks_15_images_4_header','Excellent Finish ± 0.005\"'),(190579,6964,'_content_blocks_15_images_4_header','field_6170d8f49800f'),(190580,6964,'content_blocks_15_images_4_description',''),(190581,6964,'_content_blocks_15_images_4_description','field_6170d90398010'),(190582,6964,'content_blocks_15_images','5'),(190583,6964,'_content_blocks_15_images','field_6170d8df9800d'),(190584,6964,'content_blocks_16_header','Effect of Nozzle Height'),(190585,6964,'_content_blocks_16_header','field_6170d8ba9800b'),(190586,6964,'content_blocks_16_description','For best cut quality, an optimum distance between the nozzle and the work piece should be maintained. Typically, between 0.0625\" and 0.125\" (1.5 – 3.0 mm) is the optimum height for abrasive waterjet cutting. As the distance increases above 0.125\", rounding on the top edge of the cut will result. This occurs because the waterjet stream looses coherence as it travels through open air. Increased nozzle height will also result in increased kerf angle. If the distance between the nozzle and the work piece is increased by ¼\", cutting speeds must be reduced by approximately 20% to achieve similar results with respect to tolerance and edge quality. Automatic height control is the most reliable and accurate way to maintain proper standoff distance. Figure 7 shows that if the nozzle height is increased too far, the jet will not have enough power to fully penetrate material that it would easily cut at much lower heights.'),(190587,6964,'_content_blocks_16_description','field_6170d8cd9800c'),(190588,6964,'content_blocks_16_images_0_image','2838'),(190589,6964,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(190590,6964,'content_blocks_16_images_0_header',''),(190591,6964,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(190592,6964,'content_blocks_16_images_0_description','Figure 6 - 3/4\" Aluminum with cuts at various nozzle heights, same speed'),(190593,6964,'_content_blocks_16_images_0_description','field_6170d90398010'),(190594,6964,'content_blocks_16_images_1_image','2839'),(190595,6964,'_content_blocks_16_images_1_image','field_6170d8e99800e'),(190596,6964,'content_blocks_16_images_1_header',''),(190597,6964,'_content_blocks_16_images_1_header','field_6170d8f49800f'),(190598,6964,'content_blocks_16_images_1_description','Figure 7 - Increasing nozzle height to point of no jet penetration'),(190599,6964,'_content_blocks_16_images_1_description','field_6170d90398010'),(190600,6964,'content_blocks_16_images','2'),(190601,6964,'_content_blocks_16_images','field_6170d8df9800d'),(190602,6964,'content_blocks_17_header','Effect of speed on inside corners'),(190603,6964,'_content_blocks_17_header','field_6170d8ba9800b'),(190604,6964,'content_blocks_17_description','Since the waterjet is a non-rigid cutting tool, inside corners on parts can exhibit a certain amount of overcut on the bottom, or exit, side of the part. This can be reduced by decelerating into the corner and slowly accelerating, allowing the bottom portion of the jet to catch up with the top portion around the corner. The waterjet control must have the ability to do this automatically.'),(190605,6964,'_content_blocks_17_description','field_6170d8cd9800c'),(190606,6964,'content_blocks_17_images_0_image','6963'),(190607,6964,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(190608,6964,'content_blocks_17_images_0_header','missing Images'),(190609,6964,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(190610,6964,'content_blocks_17_images_0_description','Figure 8 - Corner speed too fast'),(190611,6964,'_content_blocks_17_images_0_description','field_6170d90398010'),(190612,6964,'content_blocks_17_images','1'),(190613,6964,'_content_blocks_17_images','field_6170d8df9800d'),(190614,6964,'content_blocks_18_header','Tight radii'),(190615,6964,'_content_blocks_18_header','field_6170d8ba9800b'),(190616,6964,'content_blocks_18_description','Since the waterjet stream is a round tool, with a diameter between 0.030\" and 0.040\" (0.76 mm and 1.02 mm) for abrasive waterjet cutting, creating any inside corner that is perfectly square is impossible. CAM software will typically read geometries and give a user the option to automatically place a very small radius on these corners. This will avoid damaging the part and reduce processing time, as radii are faster to cut than square corners. For very acute angles, the actual part that is cut may differ significantly from the original drawing and should be considered for form, fit and function before processing.'),(190617,6964,'_content_blocks_18_description','field_6170d8cd9800c'),(190618,6964,'content_blocks_18_images_0_image','2840'),(190619,6964,'_content_blocks_18_images_0_image','field_6170d8e99800e'),(190620,6964,'content_blocks_18_images_0_header',''),(190621,6964,'_content_blocks_18_images_0_header','field_6170d8f49800f'),(190622,6964,'content_blocks_18_images_0_description',''),(190623,6964,'_content_blocks_18_images_0_description','field_6170d90398010'),(190624,6964,'content_blocks_18_images','1'),(190625,6964,'_content_blocks_18_images','field_6170d8df9800d'),(190626,6964,'content_blocks_19_header','Lead-in and Lead-out types'),(190627,6964,'_content_blocks_19_header','field_6170d8ba9800b'),(190628,6964,'content_blocks_19_description','Piercing in the scrap area of material and \"leading-in\" to the actual geometry to cut is standard operating procedure in most waterjet applications. This avoids placing a large blow-out blemish from the initial piercing on the surface of the part. At the end of a cut, a lead-out may be required to remove any \"nib\" from the lead-in area.\r\n\r\nVarious types of lead-ins and lead-outs can be experimented with for different materials and thicknesses. Figure 9 shows a few examples of lead-ins and leads-outs.'),(190629,6964,'_content_blocks_19_description','field_6170d8cd9800c'),(190630,6964,'content_blocks_19_images_0_image','2842'),(190631,6964,'_content_blocks_19_images_0_image','field_6170d8e99800e'),(190632,6964,'content_blocks_19_images_0_header','Different lead-in/lead-out types'),(190633,6964,'_content_blocks_19_images_0_header','field_6170d8f49800f'),(190634,6964,'content_blocks_19_images_0_description','Number 1 (straight line lead-in with very short straight line lead-out) is desirable for any sharp corner.\r\n\r\nNumber 2 (arc lead-in with short arc lead-out) is good for thinner and softer materials.\r\n\r\nNumber 3 (straight line lead in with no lead-out) gives good results on thicker, harder material.\r\n\r\nNumber 4 is an example of a straight line lead in with short arc lead-out. CAM software should have the flexibility to combine different types of lead-ins and lead-outs should the user wish to experiment.'),(190635,6964,'_content_blocks_19_images_0_description','field_6170d90398010'),(190636,6964,'content_blocks_19_images','1'),(190637,6964,'_content_blocks_19_images','field_6170d8df9800d'),(190638,6964,'content_blocks_20_header','Reducing lead-in/lead-out witness marks'),(190639,6964,'_content_blocks_20_header','field_6170d8ba9800b'),(190640,6964,'content_blocks_20_description','At the end of a cut, a small nib may remain on the bottom portion of the cut in the lead-in/lead-out area. Because of the lagging effect discussed previously, when the jet reaches the end of the cut, the top portion of the jet will find the path of least resistance, and effectively \"jump over\" a small bit of material leaving a nib. With the more sophisticated controls and software available today, this can be reduced by decelerating at the end of the cut to allow the bottom portion of the jet to catch up with the top before reaching the end of the cut. Figure 10 below shows examples of a large nib because of too much speed at the end of a cut and an example of a minimal witness mark with appropriate slow down at the end of the cut.'),(190641,6964,'_content_blocks_20_description','field_6170d8cd9800c'),(190642,6964,'content_blocks_20_images_0_image','2843'),(190643,6964,'_content_blocks_20_images_0_image','field_6170d8e99800e'),(190644,6964,'content_blocks_20_images_0_header','Bad part on left showing excessive nib.'),(190645,6964,'_content_blocks_20_images_0_header','field_6170d8f49800f'),(190646,6964,'content_blocks_20_images_0_description',''),(190647,6964,'_content_blocks_20_images_0_description','field_6170d90398010'),(190648,6964,'content_blocks_20_images_1_image','2844'),(190649,6964,'_content_blocks_20_images_1_image','field_6170d8e99800e'),(190650,6964,'content_blocks_20_images_1_header','Good part on right with minimal witness mark'),(190651,6964,'_content_blocks_20_images_1_header','field_6170d8f49800f'),(190652,6964,'content_blocks_20_images_1_description',''),(190653,6964,'_content_blocks_20_images_1_description','field_6170d90398010'),(190654,6964,'content_blocks_20_images','2'),(190655,6964,'_content_blocks_20_images','field_6170d8df9800d'),(190656,6964,'content_blocks_21_header','Waterjet stream\'s effect on accuracy'),(190657,6964,'_content_blocks_21_header','field_6170d8ba9800b'),(190658,6964,'content_blocks_21_description','Mixing tubes are made of extremely hard materials such as sintered boride or more commonly composite tungsten carbide. However, the nozzles are subject to wear and their cost must be taken into consideration for job costing. The orifice of a mixing tube will typically increase in diameter by about 0.0001\" per hour of cutting because of the erosion of the abrasive flowing through the nozzle. If this wear occurs in an even fashion, up to 120 hours of cutting can be realized with a nozzle. The biggest factor affecting nozzle wear is the material from which they are made. Controls allow for compensating for this wear by allowing the operator to change the tool offset.\r\n\r\nIf the wear of the nozzle is not symmetrical, the waterjet stream will also not be round. This will result in wider tolerances when cutting in a certain direction.\r\n\r\nThe tolerance requirements of a job will dictate the actual number of hours a user can expect from a nozzle. The nozzle can, of course, be set aside and used later for looser tolerance jobs. Control software should allow the ability to track hours on individual components to make consumable management easier. See Figure 12 below for an example of orifice and mixing tube tracking.'),(190659,6964,'_content_blocks_21_description','field_6170d8cd9800c'),(190660,6964,'content_blocks_21_images_0_image',''),(190661,6964,'_content_blocks_21_images_0_image','field_6170d8e99800e'),(190662,6964,'content_blocks_21_images_0_header','Need Image'),(190663,6964,'_content_blocks_21_images_0_header','field_6170d8f49800f'),(190664,6964,'content_blocks_21_images_0_description',''),(190665,6964,'_content_blocks_21_images_0_description','field_6170d90398010'),(190666,6964,'content_blocks_21_images_1_image','2845'),(190667,6964,'_content_blocks_21_images_1_image','field_6170d8e99800e'),(190668,6964,'content_blocks_21_images_1_header','Orifice on right is off-center.'),(190669,6964,'_content_blocks_21_images_1_header','field_6170d8f49800f'),(190670,6964,'content_blocks_21_images_1_description',''),(190671,6964,'_content_blocks_21_images_1_description','field_6170d90398010'),(190672,6964,'content_blocks_21_images','2'),(190673,6964,'_content_blocks_21_images','field_6170d8df9800d'),(190675,3569,'content_blocks_17_images_0_image','6963'),(190676,3468,'content_blocks_17_images_0_image','6963'),(190677,466,'_edit_lock','1646928490:3'),(190678,6965,'_wp_attached_file','2021/09/L-Series-water-only-waterjet-L3025-Dual5-Axis.jpg'),(190679,6965,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:1200;s:6:\"height\";i:675;s:4:\"file\";s:57:\"2021/09/L-Series-water-only-waterjet-L3025-Dual5-Axis.jpg\";s:5:\"sizes\";a:4:{s:6:\"medium\";a:4:{s:4:\"file\";s:57:\"L-Series-water-only-waterjet-L3025-Dual5-Axis-300x169.jpg\";s:5:\"width\";i:300;s:6:\"height\";i:169;s:9:\"mime-type\";s:10:\"image/jpeg\";}s:5:\"large\";a:4:{s:4:\"file\";s:58:\"L-Series-water-only-waterjet-L3025-Dual5-Axis-1024x576.jpg\";s:5:\"width\";i:1024;s:6:\"height\";i:576;s:9:\"mime-type\";s:10:\"image/jpeg\";}s:9:\"thumbnail\";a:4:{s:4:\"file\";s:57:\"L-Series-water-only-waterjet-L3025-Dual5-Axis-150x150.jpg\";s:5:\"width\";i:150;s:6:\"height\";i:150;s:9:\"mime-type\";s:10:\"image/jpeg\";}s:12:\"medium_large\";a:4:{s:4:\"file\";s:57:\"L-Series-water-only-waterjet-L3025-Dual5-Axis-768x432.jpg\";s:5:\"width\";i:768;s:6:\"height\";i:432;s:9:\"mime-type\";s:10:\"image/jpeg\";}}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:10:\"1646910187\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"1\";s:8:\"keywords\";a:0:{}}}'),(190680,6965,'_wp_attachment_image_alt','L-Series water-only waterjet L3025 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mixing tube'),(190688,6966,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2829;}}'),(190689,6967,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2829;}}'),(190690,6968,'hero_gallery',''),(190691,6968,'_hero_gallery','field_60c23d554e4a3'),(190692,6968,'hero_banner','6932'),(190693,6968,'_hero_banner','field_6170dbe179470'),(190694,6968,'page_title','Precision and Quality'),(190695,6968,'_page_title','field_6170d88998008'),(190696,6968,'page_description',''),(190697,6968,'_page_description','field_6170d89398009'),(190698,6968,'content_blocks_0_header','Overview'),(190699,6968,'_content_blocks_0_header','field_6170d8ba9800b'),(190700,6968,'content_blocks_0_description','For successful abrasive waterjet cutting, there are several factors at the cutting head that determine the precision and quality of the waterjet stream and will affect the quality of part you are able to cut with an abrasive waterjet. There are other factors that will go into cutting a precise and accurate part (machine design, controls, software and high-pressure pump) that will be discussed in other chapters. This chapter will focus on the cutting head and the waterjet as it interacts with the work piece.'),(190701,6968,'_content_blocks_0_description','field_6170d8cd9800c'),(190702,6968,'content_blocks_0_images',''),(190703,6968,'_content_blocks_0_images','field_6170d8df9800d'),(190704,6968,'content_blocks_1_header','Factors affecting precision & quality'),(190705,6968,'_content_blocks_1_header','field_6170d8ba9800b'),(190706,6968,'content_blocks_1_description','Figure 1 - Abrasive and Water Only Waterjet Cutting Heads'),(190707,6968,'_content_blocks_1_description','field_6170d8cd9800c'),(190708,6968,'content_blocks_1_images_0_image','2830'),(190709,6968,'_content_blocks_1_images_0_image','field_6170d8e99800e'),(190710,6968,'content_blocks_1_images_0_header',''),(190711,6968,'_content_blocks_1_images_0_header','field_6170d8f49800f'),(190712,6968,'content_blocks_1_images_0_description',''),(190713,6968,'_content_blocks_1_images_0_description','field_6170d90398010'),(190714,6968,'content_blocks_1_images_1_image','2831'),(190715,6968,'_content_blocks_1_images_1_image','field_6170d8e99800e'),(190716,6968,'content_blocks_1_images_1_header',''),(190717,6968,'_content_blocks_1_images_1_header','field_6170d8f49800f'),(190718,6968,'content_blocks_1_images_1_description',''),(190719,6968,'_content_blocks_1_images_1_description','field_6170d90398010'),(190720,6968,'content_blocks_1_images','2'),(190721,6968,'_content_blocks_1_images','field_6170d8df9800d'),(190722,6968,'content_blocks_2_header','1 - Abrasive mixing tube length'),(190723,6968,'_content_blocks_2_header','field_6170d8ba9800b'),(190724,6968,'content_blocks_2_description','A longer abrasive mixing tube (a.k.a. abrasive nozzle) produces a more coherent waterjet stream. The optimum mixing tube length is 3\" - 4\" (75 mm - 100 mm).'),(190725,6968,'_content_blocks_2_description','field_6170d8cd9800c'),(190726,6968,'content_blocks_2_images',''),(190727,6968,'_content_blocks_2_images','field_6170d8df9800d'),(190728,6968,'content_blocks_3_header','2 - Alignment of components'),(190729,6968,'_content_blocks_3_header','field_6170d8ba9800b'),(190730,6968,'content_blocks_3_description','The orifice, mixing chamber and abrasive nozzle must be precisely machined and fit perfectly together to avoid damage of consumables by the waterjet stream.'),(190731,6968,'_content_blocks_3_description','field_6170d8cd9800c'),(190732,6968,'content_blocks_3_images',''),(190733,6968,'_content_blocks_3_images','field_6170d8df9800d'),(190734,6968,'content_blocks_4_header','3 - Precise orifice'),(190735,6968,'_content_blocks_4_header','field_6170d8ba9800b'),(190736,6968,'content_blocks_4_description','The inside of the abrasive nozzle must be machined to ensure perfect alignment with the waterjet stream. See \"Waterjet stream\'s effect on accuracy\" section of this chapter for more information.'),(190737,6968,'_content_blocks_4_description','field_6170d8cd9800c'),(190738,6968,'content_blocks_4_images',''),(190739,6968,'_content_blocks_4_images','field_6170d8df9800d'),(190740,6968,'content_blocks_5_header','4 - Diameter of stream'),(190741,6968,'_content_blocks_5_header','field_6170d8ba9800b'),(190742,6968,'content_blocks_5_description','A small diameter waterjet stream, as produced by a .010\" (0.25 mm) orifice produces an efficient, high-quality stream. As a trade-off, cutting speeds are slower than when using a 0.014\" (0.36 mm) or larger orifice, since less water and abrasive are used. See Chapter 2 \"Relationship Parameters\" for more information on orifice selection.'),(190743,6968,'_content_blocks_5_description','field_6170d8cd9800c'),(190744,6968,'content_blocks_5_images',''),(190745,6968,'_content_blocks_5_images','field_6170d8df9800d'),(190746,6968,'content_blocks_6_header','5 - Low, controlled stand-off from work'),(190747,6968,'_content_blocks_6_header','field_6170d8ba9800b'),(190748,6968,'content_blocks_6_description','Maintaining a close distance between the nozzle and the work piece, between 0.040\" and 0.060\" (1.0 - 1.5 mm), is critical for producing accurate parts while also getting the maximum efficiency from the waterjet. Cutting closer to the material limits the amount of atmosphere that the jet has to travel through before reaching the work piece. This limits the expansion of the waterjet stream, since as the jet expands, the effective power of the jet is reduced. Cutting speeds will need to be reduced to compensate. If the distance between the nozzle and the work piece is increased by ¼\", cutting speeds must be reduced by approximately 20% to achieve similar results with respect to tolerance and edge quality. Cutting under water with CNC height control will allow for ultimate control of the waterjet stream.\r\n\r\nSee effect of nozzle height below for more information.'),(190749,6968,'_content_blocks_6_description','field_6170d8cd9800c'),(190750,6968,'content_blocks_6_images',''),(190751,6968,'_content_blocks_6_images','field_6170d8df9800d'),(190752,6968,'content_blocks_7_header','Creation of the abrasive waterjet stream'),(190753,6968,'_content_blocks_7_header','field_6170d8ba9800b'),(190754,6968,'content_blocks_7_description','Following is a description of how the abrasive waterjet stream is created in the cutting head. The numbers indicated below refer to the numbers in Figure 2.'),(190755,6968,'_content_blocks_7_description','field_6170d8cd9800c'),(190756,6968,'content_blocks_7_images_0_image','2831'),(190757,6968,'_content_blocks_7_images_0_image','field_6170d8e99800e'),(190758,6968,'content_blocks_7_images_0_header',''),(190759,6968,'_content_blocks_7_images_0_header','field_6170d8f49800f'),(190760,6968,'content_blocks_7_images_0_description',''),(190761,6968,'_content_blocks_7_images_0_description','field_6170d90398010'),(190762,6968,'content_blocks_7_images','1'),(190763,6968,'_content_blocks_7_images','field_6170d8df9800d'),(190764,6968,'content_blocks_8_header','1 - Water Pressure'),(190765,6968,'_content_blocks_8_header','field_6170d8ba9800b'),(190766,6968,'content_blocks_8_description','Water pressurized at 50,000 psi or greater enters the cutting head at relatively slow speed, in the order of a few feet per second. (See \"How It Works\" for more information on how this water pressure is created and transmitted to the cutting head.)'),(190767,6968,'_content_blocks_8_description','field_6170d8cd9800c'),(190768,6968,'content_blocks_8_images',''),(190769,6968,'_content_blocks_8_images','field_6170d8df9800d'),(190770,6968,'content_blocks_9_header','Stream Conversion'),(190771,6968,'_content_blocks_9_header','field_6170d8ba9800b'),(190772,6968,'content_blocks_9_description','The water is forced through an orifice that has a small diameter orifice, anywhere from 0.004\" to 0.045\" depending upon the application. These orifices are made of extremely hard material, such as diamond, sapphire or ruby. This step converts the water stream from a high pressure stream to a high velocity stream. At this point the water is moving in excess of 2200 miles per hour (3657 kilometers per hour).'),(190773,6968,'_content_blocks_9_description','field_6170d8cd9800c'),(190774,6968,'content_blocks_9_images',''),(190775,6968,'_content_blocks_9_images','field_6170d8df9800d'),(190776,6968,'content_blocks_10_header','3 - Venturi Effect'),(190777,6968,'_content_blocks_10_header','field_6170d8ba9800b'),(190778,6968,'content_blocks_10_description','The high velocity of the jet creates a Venturi effect, or vacuum, in the mixing chamber located immediately beneath the orifice. Abrasive, typically garnet, is metered from a mini-hopper through a plastic tube down to the cutting head and is sucked into the waterjet stream in the mixing chamber. Cutting speed will increase with more abrasive until a saturation point is reached where speed starts to decrease. If the abrasive amount is increased too high, ultimately the mixing tube will clog.\r\nOne of the exciting advancements in waterjet cutting in the past few years is the appearance on CNC- controlled abrasive metering systems. These systems precisely control the amount of abrasive that is allowed to flow to the cutting head. During the piercing process, cutting pressure and abrasive amount are reduced and the cutting head makes small, circular motions in the X and Y axes. This piercing procedure allows for difficult applications, such as piercing of glass and stone, to be processed with relative ease.'),(190779,6968,'_content_blocks_10_description','field_6170d8cd9800c'),(190780,6968,'content_blocks_10_images',''),(190781,6968,'_content_blocks_10_images','field_6170d8df9800d'),(190782,6968,'content_blocks_11_header','4 - Waterjet stream & abrasive mixture'),(190783,6968,'_content_blocks_11_header','field_6170d8ba9800b'),(190784,6968,'content_blocks_11_description','The abrasive is fully mixed in the waterjet stream and is accelerated to approximately the speed of the waterjet stream. This step does steal some energy from the waterjet stream, slowing it down slightly.'),(190785,6968,'_content_blocks_11_description','field_6170d8cd9800c'),(190786,6968,'content_blocks_11_images',''),(190787,6968,'_content_blocks_11_images','field_6170d8df9800d'),(190788,6968,'content_blocks_12_header','5 - Accelerated Erosion'),(190789,6968,'_content_blocks_12_header','field_6170d8ba9800b'),(190790,6968,'content_blocks_12_description','The abrasive waterjet stream exits the mixing tube with extreme speed and power. The abrasive erodes the material to be cut. The process is referred to as \"abrasive waterjet cutting\" because it is the abrasive that is actually doing the cutting. The water\'s role is simply to give speed and power to the abrasive. In pure waterjet cutting, used for soft materials like foam and food, the force of the waterjet stream alone is enough to cut the material and abrasive is not required.'),(190791,6968,'_content_blocks_12_description','field_6170d8cd9800c'),(190792,6968,'content_blocks_12_images',''),(190793,6968,'_content_blocks_12_images','field_6170d8df9800d'),(190794,6968,'content_blocks_13_header','Affect of speed upon kerf angle'),(190795,6968,'_content_blocks_13_header','field_6170d8ba9800b'),(190796,6968,'content_blocks_13_description','Kerf angle, or bevel, refers to the dimensional difference between the top and bottom of the cut cross-section. Cutting too fast will result in a wider kerf width at the top of the cut cross-section and a narrower kerf width at the bottom of the zone. In Fig. 3, from left to right, cuts were done at 26 inches per minute (ipm), 14 ipm and 9.7 ipm (660 millimeters per minute [mm/min], 355 mm/min and 246 mm/min). All other parameters were held constant (pressure 60 kpsi, 0.060\" standoff distance, 1.3 lb/min abrasive [4134 bar, 1.5mm and 600 grams/min]). At the top of the cut, kerf width was similar, around 0.044\" (1.12 mm). The difference between top and bottom going from left to right was 0.017\", 0.013\" and 0.011\" (0.43 mm, 0.33 mm and 0.28 mm). This shows the decrease in angularity as speed decreases.\r\n\r\nFigure 3 - 3/4\" (20 mm) Aluminum with 3 different cut speeds'),(190797,6968,'_content_blocks_13_description','field_6170d8cd9800c'),(190798,6968,'content_blocks_13_images_0_image','2832'),(190799,6968,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(190800,6968,'content_blocks_13_images_0_header','High Speed, Widest Kerf at Top, Narrowest aat Bottom'),(190801,6968,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(190802,6968,'content_blocks_13_images_0_description',''),(190803,6968,'_content_blocks_13_images_0_description','field_6170d90398010'),(190804,6968,'content_blocks_13_images_1_image','2833'),(190805,6968,'_content_blocks_13_images_1_image','field_6170d8e99800e'),(190806,6968,'content_blocks_13_images_1_header','Medium Speed, Wider Kerf width at top than at bottom'),(190807,6968,'_content_blocks_13_images_1_header','field_6170d8f49800f'),(190808,6968,'content_blocks_13_images_1_description',''),(190809,6968,'_content_blocks_13_images_1_description','field_6170d90398010'),(190810,6968,'content_blocks_13_images_2_image','2834'),(190811,6968,'_content_blocks_13_images_2_image','field_6170d8e99800e'),(190812,6968,'content_blocks_13_images_2_header','Slower Speed, Similar width Kerf at top and bottom'),(190813,6968,'_content_blocks_13_images_2_header','field_6170d8f49800f'),(190814,6968,'content_blocks_13_images_2_description',''),(190815,6968,'_content_blocks_13_images_2_description','field_6170d90398010'),(190816,6968,'content_blocks_13_images','3'),(190817,6968,'_content_blocks_13_images','field_6170d8df9800d'),(190818,6968,'content_blocks_14_header',''),(190819,6968,'_content_blocks_14_header','field_6170d8ba9800b'),(190820,6968,'content_blocks_14_description','The picture below shows one additional cut that was done extremely slowly (1 ipm or 25.4 mm/min) to demonstrate that when speed is decreased enough, the kerf width at the bottom of the part will be larger than at the top. In this example the kerf width at the bottom was 0.014\" (0.36 mm) larger than at the top.'),(190821,6968,'_content_blocks_14_description','field_6170d8cd9800c'),(190822,6968,'content_blocks_14_images_0_image','2835'),(190823,6968,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(190824,6968,'content_blocks_14_images_0_header','Very slow speed, Narrower kerf width at top, Wider at Bottom'),(190825,6968,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(190826,6968,'content_blocks_14_images_0_description',''),(190827,6968,'_content_blocks_14_images_0_description','field_6170d90398010'),(190828,6968,'content_blocks_14_images','1'),(190829,6968,'_content_blocks_14_images','field_6170d8df9800d'),(190830,6968,'content_blocks','22'),(190831,6968,'_content_blocks','field_6170d8ac9800a'),(190832,6968,'menu','37'),(190833,6968,'_menu','field_6170d9e059837'),(190834,6968,'display_left_column','1'),(190835,6968,'_display_left_column','field_613563c4d424b'),(190836,6968,'contact_left_heading',''),(190837,6968,'_contact_left_heading','field_60c249d645c99'),(190838,6968,'contact_left_copy',''),(190839,6968,'_contact_left_copy','field_60c24a0845c9c'),(190840,6968,'display_right_column','1'),(190841,6968,'_display_right_column','field_613563f4d424c'),(190842,6968,'contact_right_heading',''),(190843,6968,'_contact_right_heading','field_60c249e945c9a'),(190844,6968,'contact_right_copy',''),(190845,6968,'_contact_right_copy','field_60c249f845c9b'),(190846,6968,'contact_right_cta',''),(190847,6968,'_contact_right_cta','field_60c24a1945c9d'),(190848,6968,'content_blocks_15_header','Drag of waterjet stream and cut quality'),(190849,6968,'_content_blocks_15_header','field_6170d8ba9800b'),(190850,6968,'content_blocks_15_description','Increasing feedrate results in increased trail back of waterjet stream. This concept is shown in Figure 5 below. Rougher edge quality is the result of more shearing action versus erosion action of abrasive at slower speeds. Modern controllers allow the user to adjust cut quality based upon part requirements. High-precision holes can be cut slower for a smoother, straighter cut. Faster cutting speeds with rougher edge quality can be used on less critical areas.'),(190851,6968,'_content_blocks_15_description','field_6170d8cd9800c'),(190852,6968,'content_blocks_15_images_0_image','2950'),(190853,6968,'_content_blocks_15_images_0_image','field_6170d8e99800e'),(190854,6968,'content_blocks_15_images_0_header','Seperation Cut'),(190855,6968,'_content_blocks_15_images_0_header','field_6170d8f49800f'),(190856,6968,'content_blocks_15_images_0_description',''),(190857,6968,'_content_blocks_15_images_0_description','field_6170d90398010'),(190858,6968,'content_blocks_15_images_1_image','2951'),(190859,6968,'_content_blocks_15_images_1_image','field_6170d8e99800e'),(190860,6968,'content_blocks_15_images_1_header','Through Cut'),(190861,6968,'_content_blocks_15_images_1_header','field_6170d8f49800f'),(190862,6968,'content_blocks_15_images_1_description',''),(190863,6968,'_content_blocks_15_images_1_description','field_6170d90398010'),(190864,6968,'content_blocks_15_images_2_image','2952'),(190865,6968,'_content_blocks_15_images_2_image','field_6170d8e99800e'),(190866,6968,'content_blocks_15_images_2_header','Clean Cut ± 0.010\"'),(190867,6968,'_content_blocks_15_images_2_header','field_6170d8f49800f'),(190868,6968,'content_blocks_15_images_2_description',''),(190869,6968,'_content_blocks_15_images_2_description','field_6170d90398010'),(190870,6968,'content_blocks_15_images_3_image','2953'),(190871,6968,'_content_blocks_15_images_3_image','field_6170d8e99800e'),(190872,6968,'content_blocks_15_images_3_header','Good Finish'),(190873,6968,'_content_blocks_15_images_3_header','field_6170d8f49800f'),(190874,6968,'content_blocks_15_images_3_description',''),(190875,6968,'_content_blocks_15_images_3_description','field_6170d90398010'),(190876,6968,'content_blocks_15_images_4_image','2954'),(190877,6968,'_content_blocks_15_images_4_image','field_6170d8e99800e'),(190878,6968,'content_blocks_15_images_4_header','Excellent Finish ± 0.005\"'),(190879,6968,'_content_blocks_15_images_4_header','field_6170d8f49800f'),(190880,6968,'content_blocks_15_images_4_description',''),(190881,6968,'_content_blocks_15_images_4_description','field_6170d90398010'),(190882,6968,'content_blocks_15_images','5'),(190883,6968,'_content_blocks_15_images','field_6170d8df9800d'),(190884,6968,'content_blocks_16_header','Effect of Nozzle Height'),(190885,6968,'_content_blocks_16_header','field_6170d8ba9800b'),(190886,6968,'content_blocks_16_description','For best cut quality, an optimum distance between the nozzle and the work piece should be maintained. Typically, between 0.0625\" and 0.125\" (1.5 – 3.0 mm) is the optimum height for abrasive waterjet cutting. As the distance increases above 0.125\", rounding on the top edge of the cut will result. This occurs because the waterjet stream looses coherence as it travels through open air. Increased nozzle height will also result in increased kerf angle. If the distance between the nozzle and the work piece is increased by ¼\", cutting speeds must be reduced by approximately 20% to achieve similar results with respect to tolerance and edge quality. Automatic height control is the most reliable and accurate way to maintain proper standoff distance. Figure 7 shows that if the nozzle height is increased too far, the jet will not have enough power to fully penetrate material that it would easily cut at much lower heights.'),(190887,6968,'_content_blocks_16_description','field_6170d8cd9800c'),(190888,6968,'content_blocks_16_images_0_image','2838'),(190889,6968,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(190890,6968,'content_blocks_16_images_0_header',''),(190891,6968,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(190892,6968,'content_blocks_16_images_0_description','Figure 6 - 3/4\" Aluminum with cuts at various nozzle heights, same speed'),(190893,6968,'_content_blocks_16_images_0_description','field_6170d90398010'),(190894,6968,'content_blocks_16_images_1_image','2839'),(190895,6968,'_content_blocks_16_images_1_image','field_6170d8e99800e'),(190896,6968,'content_blocks_16_images_1_header',''),(190897,6968,'_content_blocks_16_images_1_header','field_6170d8f49800f'),(190898,6968,'content_blocks_16_images_1_description','Figure 7 - Increasing nozzle height to point of no jet penetration'),(190899,6968,'_content_blocks_16_images_1_description','field_6170d90398010'),(190900,6968,'content_blocks_16_images','2'),(190901,6968,'_content_blocks_16_images','field_6170d8df9800d'),(190902,6968,'content_blocks_17_header','Effect of speed on inside corners'),(190903,6968,'_content_blocks_17_header','field_6170d8ba9800b'),(190904,6968,'content_blocks_17_description','Since the waterjet is a non-rigid cutting tool, inside corners on parts can exhibit a certain amount of overcut on the bottom, or exit, side of the part. This can be reduced by decelerating into the corner and slowly accelerating, allowing the bottom portion of the jet to catch up with the top portion around the corner. The waterjet control must have the ability to do this automatically.'),(190905,6968,'_content_blocks_17_description','field_6170d8cd9800c'),(190906,6968,'content_blocks_17_images_0_image','6963'),(190907,6968,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(190908,6968,'content_blocks_17_images_0_header',''),(190909,6968,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(190910,6968,'content_blocks_17_images_0_description','Figure 8 - Corner speed too fast'),(190911,6968,'_content_blocks_17_images_0_description','field_6170d90398010'),(190912,6968,'content_blocks_17_images','1'),(190913,6968,'_content_blocks_17_images','field_6170d8df9800d'),(190914,6968,'content_blocks_18_header','Tight radii'),(190915,6968,'_content_blocks_18_header','field_6170d8ba9800b'),(190916,6968,'content_blocks_18_description','Since the waterjet stream is a round tool, with a diameter between 0.030\" and 0.040\" (0.76 mm and 1.02 mm) for abrasive waterjet cutting, creating any inside corner that is perfectly square is impossible. CAM software will typically read geometries and give a user the option to automatically place a very small radius on these corners. This will avoid damaging the part and reduce processing time, as radii are faster to cut than square corners. For very acute angles, the actual part that is cut may differ significantly from the original drawing and should be considered for form, fit and function before processing.'),(190917,6968,'_content_blocks_18_description','field_6170d8cd9800c'),(190918,6968,'content_blocks_18_images_0_image','2840'),(190919,6968,'_content_blocks_18_images_0_image','field_6170d8e99800e'),(190920,6968,'content_blocks_18_images_0_header',''),(190921,6968,'_content_blocks_18_images_0_header','field_6170d8f49800f'),(190922,6968,'content_blocks_18_images_0_description',''),(190923,6968,'_content_blocks_18_images_0_description','field_6170d90398010'),(190924,6968,'content_blocks_18_images','1'),(190925,6968,'_content_blocks_18_images','field_6170d8df9800d'),(190926,6968,'content_blocks_19_header','Lead-in and Lead-out types'),(190927,6968,'_content_blocks_19_header','field_6170d8ba9800b'),(190928,6968,'content_blocks_19_description','Piercing in the scrap area of material and \"leading-in\" to the actual geometry to cut is standard operating procedure in most waterjet applications. This avoids placing a large blow-out blemish from the initial piercing on the surface of the part. At the end of a cut, a lead-out may be required to remove any \"nib\" from the lead-in area.\r\n\r\nVarious types of lead-ins and lead-outs can be experimented with for different materials and thicknesses. Figure 9 shows a few examples of lead-ins and leads-outs.'),(190929,6968,'_content_blocks_19_description','field_6170d8cd9800c'),(190930,6968,'content_blocks_19_images_0_image','2842'),(190931,6968,'_content_blocks_19_images_0_image','field_6170d8e99800e'),(190932,6968,'content_blocks_19_images_0_header','Different lead-in/lead-out types'),(190933,6968,'_content_blocks_19_images_0_header','field_6170d8f49800f'),(190934,6968,'content_blocks_19_images_0_description','Number 1 (straight line lead-in with very short straight line lead-out) is desirable for any sharp corner.\r\n\r\nNumber 2 (arc lead-in with short arc lead-out) is good for thinner and softer materials.\r\n\r\nNumber 3 (straight line lead in with no lead-out) gives good results on thicker, harder material.\r\n\r\nNumber 4 is an example of a straight line lead in with short arc lead-out. CAM software should have the flexibility to combine different types of lead-ins and lead-outs should the user wish to experiment.'),(190935,6968,'_content_blocks_19_images_0_description','field_6170d90398010'),(190936,6968,'content_blocks_19_images','1'),(190937,6968,'_content_blocks_19_images','field_6170d8df9800d'),(190938,6968,'content_blocks_20_header','Reducing lead-in/lead-out witness marks'),(190939,6968,'_content_blocks_20_header','field_6170d8ba9800b'),(190940,6968,'content_blocks_20_description','At the end of a cut, a small nib may remain on the bottom portion of the cut in the lead-in/lead-out area. Because of the lagging effect discussed previously, when the jet reaches the end of the cut, the top portion of the jet will find the path of least resistance, and effectively \"jump over\" a small bit of material leaving a nib. With the more sophisticated controls and software available today, this can be reduced by decelerating at the end of the cut to allow the bottom portion of the jet to catch up with the top before reaching the end of the cut. Figure 10 below shows examples of a large nib because of too much speed at the end of a cut and an example of a minimal witness mark with appropriate slow down at the end of the cut.'),(190941,6968,'_content_blocks_20_description','field_6170d8cd9800c'),(190942,6968,'content_blocks_20_images_0_image','2843'),(190943,6968,'_content_blocks_20_images_0_image','field_6170d8e99800e'),(190944,6968,'content_blocks_20_images_0_header',''),(190945,6968,'_content_blocks_20_images_0_header','field_6170d8f49800f'),(190946,6968,'content_blocks_20_images_0_description','Figure 10 - Bad part on left showing excessive nib'),(190947,6968,'_content_blocks_20_images_0_description','field_6170d90398010'),(190948,6968,'content_blocks_20_images_1_image','2844'),(190949,6968,'_content_blocks_20_images_1_image','field_6170d8e99800e'),(190950,6968,'content_blocks_20_images_1_header',''),(190951,6968,'_content_blocks_20_images_1_header','field_6170d8f49800f'),(190952,6968,'content_blocks_20_images_1_description','Good part on right with minimal witness mark'),(190953,6968,'_content_blocks_20_images_1_description','field_6170d90398010'),(190954,6968,'content_blocks_20_images','2'),(190955,6968,'_content_blocks_20_images','field_6170d8df9800d'),(190956,6968,'content_blocks_21_header','Waterjet stream\'s effect on accuracy'),(190957,6968,'_content_blocks_21_header','field_6170d8ba9800b'),(190958,6968,'content_blocks_21_description','Mixing tubes are made of extremely hard materials such as sintered boride or more commonly composite tungsten carbide. However, the nozzles are subject to wear and their cost must be taken into consideration for job costing. The orifice of a mixing tube will typically increase in diameter by about 0.0001\" per hour of cutting because of the erosion of the abrasive flowing through the nozzle. If this wear occurs in an even fashion, up to 120 hours of cutting can be realized with a nozzle. The biggest factor affecting nozzle wear is the material from which they are made. Controls allow for compensating for this wear by allowing the operator to change the tool offset.\r\n\r\n<img src=\"http://www.wardjet.com/wp-content/uploads/2022/03/new-mixing-tube.jpg\" alt=\"new mixing tube\" width=\"272\" height=\"249\" class=\"alignnone size-full wp-image-6967\" /> <img src=\"http://www.wardjet.com/wp-content/uploads/2022/03/used-mixing-tube.jpg\" alt=\"\" width=\"280\" height=\"265\" class=\"alignnone size-full wp-image-6966\" />\r\n\r\nIf the wear of the nozzle is not symmetrical, the waterjet stream will also not be round. This will result in wider tolerances when cutting in a certain direction.\r\n\r\nThe tolerance requirements of a job will dictate the actual number of hours a user can expect from a nozzle. The nozzle can, of course, be set aside and used later for looser tolerance jobs. Control software should allow the ability to track hours on individual components to make consumable management easier. See Figure 12 below for an example of orifice and mixing tube tracking.'),(190959,6968,'_content_blocks_21_description','field_6170d8cd9800c'),(190960,6968,'content_blocks_21_images_0_image','6966'),(190961,6968,'_content_blocks_21_images_0_image','field_6170d8e99800e'),(190962,6968,'content_blocks_21_images_0_header',''),(190963,6968,'_content_blocks_21_images_0_header','field_6170d8f49800f'),(190964,6968,'content_blocks_21_images_0_description','New and used mixing tubes.'),(190965,6968,'_content_blocks_21_images_0_description','field_6170d90398010'),(190966,6968,'content_blocks_21_images_1_image','6967'),(190967,6968,'_content_blocks_21_images_1_image','field_6170d8e99800e'),(190968,6968,'content_blocks_21_images_1_header',''),(190969,6968,'_content_blocks_21_images_1_header','field_6170d8f49800f'),(190970,6968,'content_blocks_21_images_1_description','Note orifice on right is off-center'),(190971,6968,'_content_blocks_21_images_1_description','field_6170d90398010'),(190972,6968,'content_blocks_21_images','2'),(190973,6968,'_content_blocks_21_images','field_6170d8df9800d'),(190979,6969,'hero_gallery',''),(190980,6969,'_hero_gallery','field_60c23d554e4a3'),(190981,6969,'hero_banner','6932'),(190982,6969,'_hero_banner','field_6170dbe179470'),(190983,6969,'page_title','Precision and Quality'),(190984,6969,'_page_title','field_6170d88998008'),(190985,6969,'page_description',''),(190986,6969,'_page_description','field_6170d89398009'),(190987,6969,'content_blocks_0_header','Overview'),(190988,6969,'_content_blocks_0_header','field_6170d8ba9800b'),(190989,6969,'content_blocks_0_description','For successful abrasive waterjet cutting, there are several factors at the cutting head that determine the precision and quality of the waterjet stream and will affect the quality of part you are able to cut with an abrasive waterjet. There are other factors that will go into cutting a precise and accurate part (machine design, controls, software and high-pressure pump) that will be discussed in other chapters. This chapter will focus on the cutting head and the waterjet as it interacts with the work piece.'),(190990,6969,'_content_blocks_0_description','field_6170d8cd9800c'),(190991,6969,'content_blocks_0_images',''),(190992,6969,'_content_blocks_0_images','field_6170d8df9800d'),(190993,6969,'content_blocks_1_header','Factors affecting precision & quality'),(190994,6969,'_content_blocks_1_header','field_6170d8ba9800b'),(190995,6969,'content_blocks_1_description','Figure 1 - Abrasive and Water Only Waterjet Cutting Heads'),(190996,6969,'_content_blocks_1_description','field_6170d8cd9800c'),(190997,6969,'content_blocks_1_images_0_image','2830'),(190998,6969,'_content_blocks_1_images_0_image','field_6170d8e99800e'),(190999,6969,'content_blocks_1_images_0_header',''),(191000,6969,'_content_blocks_1_images_0_header','field_6170d8f49800f'),(191001,6969,'content_blocks_1_images_0_description',''),(191002,6969,'_content_blocks_1_images_0_description','field_6170d90398010'),(191003,6969,'content_blocks_1_images_1_image','2831'),(191004,6969,'_content_blocks_1_images_1_image','field_6170d8e99800e'),(191005,6969,'content_blocks_1_images_1_header',''),(191006,6969,'_content_blocks_1_images_1_header','field_6170d8f49800f'),(191007,6969,'content_blocks_1_images_1_description',''),(191008,6969,'_content_blocks_1_images_1_description','field_6170d90398010'),(191009,6969,'content_blocks_1_images','2'),(191010,6969,'_content_blocks_1_images','field_6170d8df9800d'),(191011,6969,'content_blocks_2_header','1 - Abrasive mixing tube length'),(191012,6969,'_content_blocks_2_header','field_6170d8ba9800b'),(191013,6969,'content_blocks_2_description','A longer abrasive mixing tube (a.k.a. abrasive nozzle) produces a more coherent waterjet stream. The optimum mixing tube length is 3\" - 4\" (75 mm - 100 mm).'),(191014,6969,'_content_blocks_2_description','field_6170d8cd9800c'),(191015,6969,'content_blocks_2_images',''),(191016,6969,'_content_blocks_2_images','field_6170d8df9800d'),(191017,6969,'content_blocks_3_header','2 - Alignment of components'),(191018,6969,'_content_blocks_3_header','field_6170d8ba9800b'),(191019,6969,'content_blocks_3_description','The orifice, mixing chamber and abrasive nozzle must be precisely machined and fit perfectly together to avoid damage of consumables by the waterjet stream.'),(191020,6969,'_content_blocks_3_description','field_6170d8cd9800c'),(191021,6969,'content_blocks_3_images',''),(191022,6969,'_content_blocks_3_images','field_6170d8df9800d'),(191023,6969,'content_blocks_4_header','3 - Precise orifice'),(191024,6969,'_content_blocks_4_header','field_6170d8ba9800b'),(191025,6969,'content_blocks_4_description','The inside of the abrasive nozzle must be machined to ensure perfect alignment with the waterjet stream. See \"Waterjet stream\'s effect on accuracy\" section of this chapter for more information.'),(191026,6969,'_content_blocks_4_description','field_6170d8cd9800c'),(191027,6969,'content_blocks_4_images',''),(191028,6969,'_content_blocks_4_images','field_6170d8df9800d'),(191029,6969,'content_blocks_5_header','4 - Diameter of stream'),(191030,6969,'_content_blocks_5_header','field_6170d8ba9800b'),(191031,6969,'content_blocks_5_description','A small diameter waterjet stream, as produced by a .010\" (0.25 mm) orifice produces an efficient, high-quality stream. As a trade-off, cutting speeds are slower than when using a 0.014\" (0.36 mm) or larger orifice, since less water and abrasive are used. See Chapter 2 \"Relationship Parameters\" for more information on orifice selection.'),(191032,6969,'_content_blocks_5_description','field_6170d8cd9800c'),(191033,6969,'content_blocks_5_images',''),(191034,6969,'_content_blocks_5_images','field_6170d8df9800d'),(191035,6969,'content_blocks_6_header','5 - Low, controlled stand-off from work'),(191036,6969,'_content_blocks_6_header','field_6170d8ba9800b'),(191037,6969,'content_blocks_6_description','Maintaining a close distance between the nozzle and the work piece, between 0.040\" and 0.060\" (1.0 - 1.5 mm), is critical for producing accurate parts while also getting the maximum efficiency from the waterjet. Cutting closer to the material limits the amount of atmosphere that the jet has to travel through before reaching the work piece. This limits the expansion of the waterjet stream, since as the jet expands, the effective power of the jet is reduced. Cutting speeds will need to be reduced to compensate. If the distance between the nozzle and the work piece is increased by ¼\", cutting speeds must be reduced by approximately 20% to achieve similar results with respect to tolerance and edge quality. Cutting under water with CNC height control will allow for ultimate control of the waterjet stream.\r\n\r\nSee effect of nozzle height below for more information.'),(191038,6969,'_content_blocks_6_description','field_6170d8cd9800c'),(191039,6969,'content_blocks_6_images',''),(191040,6969,'_content_blocks_6_images','field_6170d8df9800d'),(191041,6969,'content_blocks_7_header','Creation of the abrasive waterjet stream'),(191042,6969,'_content_blocks_7_header','field_6170d8ba9800b'),(191043,6969,'content_blocks_7_description','Following is a description of how the abrasive waterjet stream is created in the cutting head. The numbers indicated below refer to the numbers in Figure 2.'),(191044,6969,'_content_blocks_7_description','field_6170d8cd9800c'),(191045,6969,'content_blocks_7_images_0_image','2831'),(191046,6969,'_content_blocks_7_images_0_image','field_6170d8e99800e'),(191047,6969,'content_blocks_7_images_0_header',''),(191048,6969,'_content_blocks_7_images_0_header','field_6170d8f49800f'),(191049,6969,'content_blocks_7_images_0_description',''),(191050,6969,'_content_blocks_7_images_0_description','field_6170d90398010'),(191051,6969,'content_blocks_7_images','1'),(191052,6969,'_content_blocks_7_images','field_6170d8df9800d'),(191053,6969,'content_blocks_8_header','1 - Water Pressure'),(191054,6969,'_content_blocks_8_header','field_6170d8ba9800b'),(191055,6969,'content_blocks_8_description','Water pressurized at 50,000 psi or greater enters the cutting head at relatively slow speed, in the order of a few feet per second. (See \"How It Works\" for more information on how this water pressure is created and transmitted to the cutting head.)'),(191056,6969,'_content_blocks_8_description','field_6170d8cd9800c'),(191057,6969,'content_blocks_8_images',''),(191058,6969,'_content_blocks_8_images','field_6170d8df9800d'),(191059,6969,'content_blocks_9_header','Stream Conversion'),(191060,6969,'_content_blocks_9_header','field_6170d8ba9800b'),(191061,6969,'content_blocks_9_description','The water is forced through an orifice that has a small diameter orifice, anywhere from 0.004\" to 0.045\" depending upon the application. These orifices are made of extremely hard material, such as diamond, sapphire or ruby. This step converts the water stream from a high pressure stream to a high velocity stream. At this point the water is moving in excess of 2200 miles per hour (3657 kilometers per hour).'),(191062,6969,'_content_blocks_9_description','field_6170d8cd9800c'),(191063,6969,'content_blocks_9_images',''),(191064,6969,'_content_blocks_9_images','field_6170d8df9800d'),(191065,6969,'content_blocks_10_header','3 - Venturi Effect'),(191066,6969,'_content_blocks_10_header','field_6170d8ba9800b'),(191067,6969,'content_blocks_10_description','The high velocity of the jet creates a Venturi effect, or vacuum, in the mixing chamber located immediately beneath the orifice. Abrasive, typically garnet, is metered from a mini-hopper through a plastic tube down to the cutting head and is sucked into the waterjet stream in the mixing chamber. Cutting speed will increase with more abrasive until a saturation point is reached where speed starts to decrease. If the abrasive amount is increased too high, ultimately the mixing tube will clog.\r\nOne of the exciting advancements in waterjet cutting in the past few years is the appearance on CNC- controlled abrasive metering systems. These systems precisely control the amount of abrasive that is allowed to flow to the cutting head. During the piercing process, cutting pressure and abrasive amount are reduced and the cutting head makes small, circular motions in the X and Y axes. This piercing procedure allows for difficult applications, such as piercing of glass and stone, to be processed with relative ease.'),(191068,6969,'_content_blocks_10_description','field_6170d8cd9800c'),(191069,6969,'content_blocks_10_images',''),(191070,6969,'_content_blocks_10_images','field_6170d8df9800d'),(191071,6969,'content_blocks_11_header','4 - Waterjet stream & abrasive mixture'),(191072,6969,'_content_blocks_11_header','field_6170d8ba9800b'),(191073,6969,'content_blocks_11_description','The abrasive is fully mixed in the waterjet stream and is accelerated to approximately the speed of the waterjet stream. This step does steal some energy from the waterjet stream, slowing it down slightly.'),(191074,6969,'_content_blocks_11_description','field_6170d8cd9800c'),(191075,6969,'content_blocks_11_images',''),(191076,6969,'_content_blocks_11_images','field_6170d8df9800d'),(191077,6969,'content_blocks_12_header','5 - Accelerated Erosion'),(191078,6969,'_content_blocks_12_header','field_6170d8ba9800b'),(191079,6969,'content_blocks_12_description','The abrasive waterjet stream exits the mixing tube with extreme speed and power. The abrasive erodes the material to be cut. The process is referred to as \"abrasive waterjet cutting\" because it is the abrasive that is actually doing the cutting. The water\'s role is simply to give speed and power to the abrasive. In pure waterjet cutting, used for soft materials like foam and food, the force of the waterjet stream alone is enough to cut the material and abrasive is not required.'),(191080,6969,'_content_blocks_12_description','field_6170d8cd9800c'),(191081,6969,'content_blocks_12_images',''),(191082,6969,'_content_blocks_12_images','field_6170d8df9800d'),(191083,6969,'content_blocks_13_header','Affect of speed upon kerf angle'),(191084,6969,'_content_blocks_13_header','field_6170d8ba9800b'),(191085,6969,'content_blocks_13_description','Kerf angle, or bevel, refers to the dimensional difference between the top and bottom of the cut cross-section. Cutting too fast will result in a wider kerf width at the top of the cut cross-section and a narrower kerf width at the bottom of the zone. In Fig. 3, from left to right, cuts were done at 26 inches per minute (ipm), 14 ipm and 9.7 ipm (660 millimeters per minute [mm/min], 355 mm/min and 246 mm/min). All other parameters were held constant (pressure 60 kpsi, 0.060\" standoff distance, 1.3 lb/min abrasive [4134 bar, 1.5mm and 600 grams/min]). At the top of the cut, kerf width was similar, around 0.044\" (1.12 mm). The difference between top and bottom going from left to right was 0.017\", 0.013\" and 0.011\" (0.43 mm, 0.33 mm and 0.28 mm). This shows the decrease in angularity as speed decreases.\r\n\r\nFigure 3 - 3/4\" (20 mm) Aluminum with 3 different cut speeds'),(191086,6969,'_content_blocks_13_description','field_6170d8cd9800c'),(191087,6969,'content_blocks_13_images_0_image','2832'),(191088,6969,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(191089,6969,'content_blocks_13_images_0_header','High Speed, Widest Kerf at Top, Narrowest aat Bottom'),(191090,6969,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(191091,6969,'content_blocks_13_images_0_description',''),(191092,6969,'_content_blocks_13_images_0_description','field_6170d90398010'),(191093,6969,'content_blocks_13_images_1_image','2833'),(191094,6969,'_content_blocks_13_images_1_image','field_6170d8e99800e'),(191095,6969,'content_blocks_13_images_1_header','Medium Speed, Wider Kerf width at top than at bottom'),(191096,6969,'_content_blocks_13_images_1_header','field_6170d8f49800f'),(191097,6969,'content_blocks_13_images_1_description',''),(191098,6969,'_content_blocks_13_images_1_description','field_6170d90398010'),(191099,6969,'content_blocks_13_images_2_image','2834'),(191100,6969,'_content_blocks_13_images_2_image','field_6170d8e99800e'),(191101,6969,'content_blocks_13_images_2_header','Slower Speed, Similar width Kerf at top and bottom'),(191102,6969,'_content_blocks_13_images_2_header','field_6170d8f49800f'),(191103,6969,'content_blocks_13_images_2_description',''),(191104,6969,'_content_blocks_13_images_2_description','field_6170d90398010'),(191105,6969,'content_blocks_13_images','3'),(191106,6969,'_content_blocks_13_images','field_6170d8df9800d'),(191107,6969,'content_blocks_14_header',''),(191108,6969,'_content_blocks_14_header','field_6170d8ba9800b'),(191109,6969,'content_blocks_14_description','The picture below shows one additional cut that was done extremely slowly (1 ipm or 25.4 mm/min) to demonstrate that when speed is decreased enough, the kerf width at the bottom of the part will be larger than at the top. In this example the kerf width at the bottom was 0.014\" (0.36 mm) larger than at the top.'),(191110,6969,'_content_blocks_14_description','field_6170d8cd9800c'),(191111,6969,'content_blocks_14_images_0_image','2835'),(191112,6969,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(191113,6969,'content_blocks_14_images_0_header','Very slow speed, Narrower kerf width at top, Wider at Bottom'),(191114,6969,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(191115,6969,'content_blocks_14_images_0_description',''),(191116,6969,'_content_blocks_14_images_0_description','field_6170d90398010'),(191117,6969,'content_blocks_14_images','1'),(191118,6969,'_content_blocks_14_images','field_6170d8df9800d'),(191119,6969,'content_blocks','22'),(191120,6969,'_content_blocks','field_6170d8ac9800a'),(191121,6969,'menu','37'),(191122,6969,'_menu','field_6170d9e059837'),(191123,6969,'display_left_column','1'),(191124,6969,'_display_left_column','field_613563c4d424b'),(191125,6969,'contact_left_heading',''),(191126,6969,'_contact_left_heading','field_60c249d645c99'),(191127,6969,'contact_left_copy',''),(191128,6969,'_contact_left_copy','field_60c24a0845c9c'),(191129,6969,'display_right_column','1'),(191130,6969,'_display_right_column','field_613563f4d424c'),(191131,6969,'contact_right_heading',''),(191132,6969,'_contact_right_heading','field_60c249e945c9a'),(191133,6969,'contact_right_copy',''),(191134,6969,'_contact_right_copy','field_60c249f845c9b'),(191135,6969,'contact_right_cta',''),(191136,6969,'_contact_right_cta','field_60c24a1945c9d'),(191137,6969,'content_blocks_15_header','Drag of waterjet stream and cut quality'),(191138,6969,'_content_blocks_15_header','field_6170d8ba9800b'),(191139,6969,'content_blocks_15_description','Increasing feedrate results in increased trail back of waterjet stream. This concept is shown in Figure 5 below. Rougher edge quality is the result of more shearing action versus erosion action of abrasive at slower speeds. Modern controllers allow the user to adjust cut quality based upon part requirements. High-precision holes can be cut slower for a smoother, straighter cut. Faster cutting speeds with rougher edge quality can be used on less critical areas.'),(191140,6969,'_content_blocks_15_description','field_6170d8cd9800c'),(191141,6969,'content_blocks_15_images_0_image','2950'),(191142,6969,'_content_blocks_15_images_0_image','field_6170d8e99800e'),(191143,6969,'content_blocks_15_images_0_header','Seperation Cut'),(191144,6969,'_content_blocks_15_images_0_header','field_6170d8f49800f'),(191145,6969,'content_blocks_15_images_0_description',''),(191146,6969,'_content_blocks_15_images_0_description','field_6170d90398010'),(191147,6969,'content_blocks_15_images_1_image','2951'),(191148,6969,'_content_blocks_15_images_1_image','field_6170d8e99800e'),(191149,6969,'content_blocks_15_images_1_header','Through Cut'),(191150,6969,'_content_blocks_15_images_1_header','field_6170d8f49800f'),(191151,6969,'content_blocks_15_images_1_description',''),(191152,6969,'_content_blocks_15_images_1_description','field_6170d90398010'),(191153,6969,'content_blocks_15_images_2_image','2952'),(191154,6969,'_content_blocks_15_images_2_image','field_6170d8e99800e'),(191155,6969,'content_blocks_15_images_2_header','Clean Cut ± 0.010\"'),(191156,6969,'_content_blocks_15_images_2_header','field_6170d8f49800f'),(191157,6969,'content_blocks_15_images_2_description',''),(191158,6969,'_content_blocks_15_images_2_description','field_6170d90398010'),(191159,6969,'content_blocks_15_images_3_image','2953'),(191160,6969,'_content_blocks_15_images_3_image','field_6170d8e99800e'),(191161,6969,'content_blocks_15_images_3_header','Good Finish'),(191162,6969,'_content_blocks_15_images_3_header','field_6170d8f49800f'),(191163,6969,'content_blocks_15_images_3_description',''),(191164,6969,'_content_blocks_15_images_3_description','field_6170d90398010'),(191165,6969,'content_blocks_15_images_4_image','2954'),(191166,6969,'_content_blocks_15_images_4_image','field_6170d8e99800e'),(191167,6969,'content_blocks_15_images_4_header','Excellent Finish ± 0.005\"'),(191168,6969,'_content_blocks_15_images_4_header','field_6170d8f49800f'),(191169,6969,'content_blocks_15_images_4_description',''),(191170,6969,'_content_blocks_15_images_4_description','field_6170d90398010'),(191171,6969,'content_blocks_15_images','5'),(191172,6969,'_content_blocks_15_images','field_6170d8df9800d'),(191173,6969,'content_blocks_16_header','Effect of Nozzle Height'),(191174,6969,'_content_blocks_16_header','field_6170d8ba9800b'),(191175,6969,'content_blocks_16_description','For best cut quality, an optimum distance between the nozzle and the work piece should be maintained. Typically, between 0.0625\" and 0.125\" (1.5 – 3.0 mm) is the optimum height for abrasive waterjet cutting. As the distance increases above 0.125\", rounding on the top edge of the cut will result. This occurs because the waterjet stream looses coherence as it travels through open air. Increased nozzle height will also result in increased kerf angle. If the distance between the nozzle and the work piece is increased by ¼\", cutting speeds must be reduced by approximately 20% to achieve similar results with respect to tolerance and edge quality. Automatic height control is the most reliable and accurate way to maintain proper standoff distance. Figure 7 shows that if the nozzle height is increased too far, the jet will not have enough power to fully penetrate material that it would easily cut at much lower heights.'),(191176,6969,'_content_blocks_16_description','field_6170d8cd9800c'),(191177,6969,'content_blocks_16_images_0_image','2838'),(191178,6969,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(191179,6969,'content_blocks_16_images_0_header',''),(191180,6969,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(191181,6969,'content_blocks_16_images_0_description','Figure 6 - 3/4\" Aluminum with cuts at various nozzle heights, same speed'),(191182,6969,'_content_blocks_16_images_0_description','field_6170d90398010'),(191183,6969,'content_blocks_16_images_1_image','2839'),(191184,6969,'_content_blocks_16_images_1_image','field_6170d8e99800e'),(191185,6969,'content_blocks_16_images_1_header',''),(191186,6969,'_content_blocks_16_images_1_header','field_6170d8f49800f'),(191187,6969,'content_blocks_16_images_1_description','Figure 7 - Increasing nozzle height to point of no jet penetration'),(191188,6969,'_content_blocks_16_images_1_description','field_6170d90398010'),(191189,6969,'content_blocks_16_images','2'),(191190,6969,'_content_blocks_16_images','field_6170d8df9800d'),(191191,6969,'content_blocks_17_header','Effect of speed on inside corners'),(191192,6969,'_content_blocks_17_header','field_6170d8ba9800b'),(191193,6969,'content_blocks_17_description','Since the waterjet is a non-rigid cutting tool, inside corners on parts can exhibit a certain amount of overcut on the bottom, or exit, side of the part. This can be reduced by decelerating into the corner and slowly accelerating, allowing the bottom portion of the jet to catch up with the top portion around the corner. The waterjet control must have the ability to do this automatically.'),(191194,6969,'_content_blocks_17_description','field_6170d8cd9800c'),(191195,6969,'content_blocks_17_images_0_image','6963'),(191196,6969,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(191197,6969,'content_blocks_17_images_0_header',''),(191198,6969,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(191199,6969,'content_blocks_17_images_0_description','Figure 8 - Corner speed too fast'),(191200,6969,'_content_blocks_17_images_0_description','field_6170d90398010'),(191201,6969,'content_blocks_17_images','1'),(191202,6969,'_content_blocks_17_images','field_6170d8df9800d'),(191203,6969,'content_blocks_18_header','Tight radii'),(191204,6969,'_content_blocks_18_header','field_6170d8ba9800b'),(191205,6969,'content_blocks_18_description','Since the waterjet stream is a round tool, with a diameter between 0.030\" and 0.040\" (0.76 mm and 1.02 mm) for abrasive waterjet cutting, creating any inside corner that is perfectly square is impossible. CAM software will typically read geometries and give a user the option to automatically place a very small radius on these corners. This will avoid damaging the part and reduce processing time, as radii are faster to cut than square corners. For very acute angles, the actual part that is cut may differ significantly from the original drawing and should be considered for form, fit and function before processing.'),(191206,6969,'_content_blocks_18_description','field_6170d8cd9800c'),(191207,6969,'content_blocks_18_images_0_image','2840'),(191208,6969,'_content_blocks_18_images_0_image','field_6170d8e99800e'),(191209,6969,'content_blocks_18_images_0_header',''),(191210,6969,'_content_blocks_18_images_0_header','field_6170d8f49800f'),(191211,6969,'content_blocks_18_images_0_description',''),(191212,6969,'_content_blocks_18_images_0_description','field_6170d90398010'),(191213,6969,'content_blocks_18_images','1'),(191214,6969,'_content_blocks_18_images','field_6170d8df9800d'),(191215,6969,'content_blocks_19_header','Lead-in and Lead-out types'),(191216,6969,'_content_blocks_19_header','field_6170d8ba9800b'),(191217,6969,'content_blocks_19_description','Piercing in the scrap area of material and \"leading-in\" to the actual geometry to cut is standard operating procedure in most waterjet applications. This avoids placing a large blow-out blemish from the initial piercing on the surface of the part. At the end of a cut, a lead-out may be required to remove any \"nib\" from the lead-in area.\r\n\r\nVarious types of lead-ins and lead-outs can be experimented with for different materials and thicknesses. Figure 9 shows a few examples of lead-ins and leads-outs.'),(191218,6969,'_content_blocks_19_description','field_6170d8cd9800c'),(191219,6969,'content_blocks_19_images_0_image','2842'),(191220,6969,'_content_blocks_19_images_0_image','field_6170d8e99800e'),(191221,6969,'content_blocks_19_images_0_header','Different lead-in/lead-out types'),(191222,6969,'_content_blocks_19_images_0_header','field_6170d8f49800f'),(191223,6969,'content_blocks_19_images_0_description','Number 1 (straight line lead-in with very short straight line lead-out) is desirable for any sharp corner.\r\n\r\nNumber 2 (arc lead-in with short arc lead-out) is good for thinner and softer materials.\r\n\r\nNumber 3 (straight line lead in with no lead-out) gives good results on thicker, harder material.\r\n\r\nNumber 4 is an example of a straight line lead in with short arc lead-out. CAM software should have the flexibility to combine different types of lead-ins and lead-outs should the user wish to experiment.'),(191224,6969,'_content_blocks_19_images_0_description','field_6170d90398010'),(191225,6969,'content_blocks_19_images','1'),(191226,6969,'_content_blocks_19_images','field_6170d8df9800d'),(191227,6969,'content_blocks_20_header','Reducing lead-in/lead-out witness marks'),(191228,6969,'_content_blocks_20_header','field_6170d8ba9800b'),(191229,6969,'content_blocks_20_description','At the end of a cut, a small nib may remain on the bottom portion of the cut in the lead-in/lead-out area. Because of the lagging effect discussed previously, when the jet reaches the end of the cut, the top portion of the jet will find the path of least resistance, and effectively \"jump over\" a small bit of material leaving a nib. With the more sophisticated controls and software available today, this can be reduced by decelerating at the end of the cut to allow the bottom portion of the jet to catch up with the top before reaching the end of the cut. Figure 10 below shows examples of a large nib because of too much speed at the end of a cut and an example of a minimal witness mark with appropriate slow down at the end of the cut.'),(191230,6969,'_content_blocks_20_description','field_6170d8cd9800c'),(191231,6969,'content_blocks_20_images_0_image','2843'),(191232,6969,'_content_blocks_20_images_0_image','field_6170d8e99800e'),(191233,6969,'content_blocks_20_images_0_header',''),(191234,6969,'_content_blocks_20_images_0_header','field_6170d8f49800f'),(191235,6969,'content_blocks_20_images_0_description','Figure 10 - Bad part on left showing excessive nib'),(191236,6969,'_content_blocks_20_images_0_description','field_6170d90398010'),(191237,6969,'content_blocks_20_images_1_image','2844'),(191238,6969,'_content_blocks_20_images_1_image','field_6170d8e99800e'),(191239,6969,'content_blocks_20_images_1_header',''),(191240,6969,'_content_blocks_20_images_1_header','field_6170d8f49800f'),(191241,6969,'content_blocks_20_images_1_description','Good part on right with minimal witness mark'),(191242,6969,'_content_blocks_20_images_1_description','field_6170d90398010'),(191243,6969,'content_blocks_20_images','2'),(191244,6969,'_content_blocks_20_images','field_6170d8df9800d'),(191245,6969,'content_blocks_21_header','Waterjet stream\'s effect on accuracy'),(191246,6969,'_content_blocks_21_header','field_6170d8ba9800b'),(191247,6969,'content_blocks_21_description','Mixing tubes are made of extremely hard materials such as sintered boride or more commonly composite tungsten carbide. However, the nozzles are subject to wear and their cost must be taken into consideration for job costing. The orifice of a mixing tube will typically increase in diameter by about 0.0001\" per hour of cutting because of the erosion of the abrasive flowing through the nozzle. If this wear occurs in an even fashion, up to 120 hours of cutting can be realized with a nozzle. The biggest factor affecting nozzle wear is the material from which they are made. Controls allow for compensating for this wear by allowing the operator to change the tool offset.\r\n\r\n<img class=\"alignnone size-full wp-image-6967\" src=\"http://www.wardjet.com/wp-content/uploads/2022/03/new-mixing-tube.jpg\" alt=\"new mixing tube\" width=\"280\" /> <img class=\"alignnone size-full wp-image-6966\" src=\"http://www.wardjet.com/wp-content/uploads/2022/03/used-mixing-tube.jpg\" alt=\"\" width=\"280\" />\r\n\r\n<span style=\"color: #808080;\"><em>Figure 11 - New and used mixing tubes. Note orifice on right is off-center.</em></span>\r\n\r\nIf the wear of the nozzle is not symmetrical, the waterjet stream will also not be round. This will result in wider tolerances when cutting in a certain direction.\r\n\r\nThe tolerance requirements of a job will dictate the actual number of hours a user can expect from a nozzle. The nozzle can, of course, be set aside and used later for looser tolerance jobs. Control software should allow the ability to track hours on individual components to make consumable management easier. See Figure 12 below for an example of orifice and mixing tube tracking.'),(191248,6969,'_content_blocks_21_description','field_6170d8cd9800c'),(191249,6969,'content_blocks_21_images',''),(191250,6969,'_content_blocks_21_images','field_6170d8df9800d'),(191252,3569,'content_blocks_21_images',''),(191253,3468,'content_blocks_21_images',''),(191254,6970,'_wp_attached_file','2022/03/Factors-affecting-precision-quality-2.jpg'),(191255,6970,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:475;s:6:\"height\";i:467;s:4:\"file\";s:49:\"2022/03/Factors-affecting-precision-quality-2.jpg\";s:5:\"sizes\";a:2:{s:6:\"medium\";a:4:{s:4:\"file\";s:49:\"Factors-affecting-precision-quality-2-300x295.jpg\";s:5:\"width\";i:300;s:6:\"height\";i:295;s:9:\"mime-type\";s:10:\"image/jpeg\";}s:9:\"thumbnail\";a:4:{s:4:\"file\";s:49:\"Factors-affecting-precision-quality-2-150x150.jpg\";s:5:\"width\";i:150;s:6:\"height\";i:150;s:9:\"mime-type\";s:10:\"image/jpeg\";}}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(191256,6971,'_wp_attached_file','2022/03/Factors-affecting-precision-quality-1.jpg'),(191257,6971,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:472;s:6:\"height\";i:431;s:4:\"file\";s:49:\"2022/03/Factors-affecting-precision-quality-1.jpg\";s:5:\"sizes\";a:2:{s:6:\"medium\";a:4:{s:4:\"file\";s:49:\"Factors-affecting-precision-quality-1-300x274.jpg\";s:5:\"width\";i:300;s:6:\"height\";i:274;s:9:\"mime-type\";s:10:\"image/jpeg\";}s:9:\"thumbnail\";a:4:{s:4:\"file\";s:49:\"Factors-affecting-precision-quality-1-150x150.jpg\";s:5:\"width\";i:150;s:6:\"height\";i:150;s:9:\"mime-type\";s:10:\"image/jpeg\";}}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(191258,6971,'_wp_attachment_image_alt','Factors affecting precision & quality 1'),(191259,6970,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2829;}}'),(191260,6971,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2829;}}'),(191261,6972,'hero_gallery',''),(191262,6972,'_hero_gallery','field_60c23d554e4a3'),(191263,6972,'hero_banner','6932'),(191264,6972,'_hero_banner','field_6170dbe179470'),(191265,6972,'page_title','Precision and Quality'),(191266,6972,'_page_title','field_6170d88998008'),(191267,6972,'page_description',''),(191268,6972,'_page_description','field_6170d89398009'),(191269,6972,'content_blocks_0_header','Overview'),(191270,6972,'_content_blocks_0_header','field_6170d8ba9800b'),(191271,6972,'content_blocks_0_description','For successful abrasive waterjet cutting, there are several factors at the cutting head that determine the precision and quality of the waterjet stream and will affect the quality of part you are able to cut with an abrasive waterjet. There are other factors that will go into cutting a precise and accurate part (machine design, controls, software and high-pressure pump) that will be discussed in other chapters. This chapter will focus on the cutting head and the waterjet as it interacts with the work piece.'),(191272,6972,'_content_blocks_0_description','field_6170d8cd9800c'),(191273,6972,'content_blocks_0_images',''),(191274,6972,'_content_blocks_0_images','field_6170d8df9800d'),(191275,6972,'content_blocks_1_header','Factors affecting precision & quality'),(191276,6972,'_content_blocks_1_header','field_6170d8ba9800b'),(191277,6972,'content_blocks_1_description','<img class=\"alignnone size-medium wp-image-6971\" src=\"http://www.wardjet.com/wp-content/uploads/2022/03/Factors-affecting-precision-quality-1-300x274.jpg\" alt=\"Factors affecting precision &amp; quality 1\" width=\"300\" height=\"274\" /><img class=\"alignnone size-medium wp-image-6970\" src=\"http://www.wardjet.com/wp-content/uploads/2022/03/Factors-affecting-precision-quality-2-300x295.jpg\" alt=\"\" width=\"300\" height=\"295\" />\r\n\r\n<span style=\"color: #808080;\"><em>Figure 1 - Abrasive and Water Only Waterjet Cutting Heads</em></span>'),(191278,6972,'_content_blocks_1_description','field_6170d8cd9800c'),(191279,6972,'content_blocks_1_images',''),(191280,6972,'_content_blocks_1_images','field_6170d8df9800d'),(191281,6972,'content_blocks_2_header','1 - Abrasive mixing tube length'),(191282,6972,'_content_blocks_2_header','field_6170d8ba9800b'),(191283,6972,'content_blocks_2_description','A longer abrasive mixing tube (a.k.a. abrasive nozzle) produces a more coherent waterjet stream. The optimum mixing tube length is 3\" - 4\" (75 mm - 100 mm).'),(191284,6972,'_content_blocks_2_description','field_6170d8cd9800c'),(191285,6972,'content_blocks_2_images',''),(191286,6972,'_content_blocks_2_images','field_6170d8df9800d'),(191287,6972,'content_blocks_3_header','2 - Alignment of components'),(191288,6972,'_content_blocks_3_header','field_6170d8ba9800b'),(191289,6972,'content_blocks_3_description','The orifice, mixing chamber and abrasive nozzle must be precisely machined and fit perfectly together to avoid damage of consumables by the waterjet stream.'),(191290,6972,'_content_blocks_3_description','field_6170d8cd9800c'),(191291,6972,'content_blocks_3_images',''),(191292,6972,'_content_blocks_3_images','field_6170d8df9800d'),(191293,6972,'content_blocks_4_header','3 - Precise orifice'),(191294,6972,'_content_blocks_4_header','field_6170d8ba9800b'),(191295,6972,'content_blocks_4_description','The inside of the abrasive nozzle must be machined to ensure perfect alignment with the waterjet stream. See \"Waterjet stream\'s effect on accuracy\" section of this chapter for more information.'),(191296,6972,'_content_blocks_4_description','field_6170d8cd9800c'),(191297,6972,'content_blocks_4_images',''),(191298,6972,'_content_blocks_4_images','field_6170d8df9800d'),(191299,6972,'content_blocks_5_header','4 - Diameter of stream'),(191300,6972,'_content_blocks_5_header','field_6170d8ba9800b'),(191301,6972,'content_blocks_5_description','A small diameter waterjet stream, as produced by a .010\" (0.25 mm) orifice produces an efficient, high-quality stream. As a trade-off, cutting speeds are slower than when using a 0.014\" (0.36 mm) or larger orifice, since less water and abrasive are used. See Chapter 2 \"Relationship Parameters\" for more information on orifice selection.'),(191302,6972,'_content_blocks_5_description','field_6170d8cd9800c'),(191303,6972,'content_blocks_5_images',''),(191304,6972,'_content_blocks_5_images','field_6170d8df9800d'),(191305,6972,'content_blocks_6_header','5 - Low, controlled stand-off from work'),(191306,6972,'_content_blocks_6_header','field_6170d8ba9800b'),(191307,6972,'content_blocks_6_description','Maintaining a close distance between the nozzle and the work piece, between 0.040\" and 0.060\" (1.0 - 1.5 mm), is critical for producing accurate parts while also getting the maximum efficiency from the waterjet. Cutting closer to the material limits the amount of atmosphere that the jet has to travel through before reaching the work piece. This limits the expansion of the waterjet stream, since as the jet expands, the effective power of the jet is reduced. Cutting speeds will need to be reduced to compensate. If the distance between the nozzle and the work piece is increased by ¼\", cutting speeds must be reduced by approximately 20% to achieve similar results with respect to tolerance and edge quality. Cutting under water with CNC height control will allow for ultimate control of the waterjet stream.\r\n\r\nSee effect of nozzle height below for more information.'),(191308,6972,'_content_blocks_6_description','field_6170d8cd9800c'),(191309,6972,'content_blocks_6_images',''),(191310,6972,'_content_blocks_6_images','field_6170d8df9800d'),(191311,6972,'content_blocks_7_header','Creation of the abrasive waterjet stream'),(191312,6972,'_content_blocks_7_header','field_6170d8ba9800b'),(191313,6972,'content_blocks_7_description','Following is a description of how the abrasive waterjet stream is created in the cutting head. The numbers indicated below refer to the numbers in Figure 2.'),(191314,6972,'_content_blocks_7_description','field_6170d8cd9800c'),(191315,6972,'content_blocks_7_images_0_image','2831'),(191316,6972,'_content_blocks_7_images_0_image','field_6170d8e99800e'),(191317,6972,'content_blocks_7_images_0_header',''),(191318,6972,'_content_blocks_7_images_0_header','field_6170d8f49800f'),(191319,6972,'content_blocks_7_images_0_description',''),(191320,6972,'_content_blocks_7_images_0_description','field_6170d90398010'),(191321,6972,'content_blocks_7_images','1'),(191322,6972,'_content_blocks_7_images','field_6170d8df9800d'),(191323,6972,'content_blocks_8_header','1 - Water Pressure'),(191324,6972,'_content_blocks_8_header','field_6170d8ba9800b'),(191325,6972,'content_blocks_8_description','Water pressurized at 50,000 psi or greater enters the cutting head at relatively slow speed, in the order of a few feet per second. (See \"How It Works\" for more information on how this water pressure is created and transmitted to the cutting head.)'),(191326,6972,'_content_blocks_8_description','field_6170d8cd9800c'),(191327,6972,'content_blocks_8_images',''),(191328,6972,'_content_blocks_8_images','field_6170d8df9800d'),(191329,6972,'content_blocks_9_header','Stream Conversion'),(191330,6972,'_content_blocks_9_header','field_6170d8ba9800b'),(191331,6972,'content_blocks_9_description','The water is forced through an orifice that has a small diameter orifice, anywhere from 0.004\" to 0.045\" depending upon the application. These orifices are made of extremely hard material, such as diamond, sapphire or ruby. This step converts the water stream from a high pressure stream to a high velocity stream. At this point the water is moving in excess of 2200 miles per hour (3657 kilometers per hour).'),(191332,6972,'_content_blocks_9_description','field_6170d8cd9800c'),(191333,6972,'content_blocks_9_images',''),(191334,6972,'_content_blocks_9_images','field_6170d8df9800d'),(191335,6972,'content_blocks_10_header','3 - Venturi Effect'),(191336,6972,'_content_blocks_10_header','field_6170d8ba9800b'),(191337,6972,'content_blocks_10_description','The high velocity of the jet creates a Venturi effect, or vacuum, in the mixing chamber located immediately beneath the orifice. Abrasive, typically garnet, is metered from a mini-hopper through a plastic tube down to the cutting head and is sucked into the waterjet stream in the mixing chamber. Cutting speed will increase with more abrasive until a saturation point is reached where speed starts to decrease. If the abrasive amount is increased too high, ultimately the mixing tube will clog.\r\nOne of the exciting advancements in waterjet cutting in the past few years is the appearance on CNC- controlled abrasive metering systems. These systems precisely control the amount of abrasive that is allowed to flow to the cutting head. During the piercing process, cutting pressure and abrasive amount are reduced and the cutting head makes small, circular motions in the X and Y axes. This piercing procedure allows for difficult applications, such as piercing of glass and stone, to be processed with relative ease.'),(191338,6972,'_content_blocks_10_description','field_6170d8cd9800c'),(191339,6972,'content_blocks_10_images',''),(191340,6972,'_content_blocks_10_images','field_6170d8df9800d'),(191341,6972,'content_blocks_11_header','4 - Waterjet stream & abrasive mixture'),(191342,6972,'_content_blocks_11_header','field_6170d8ba9800b'),(191343,6972,'content_blocks_11_description','The abrasive is fully mixed in the waterjet stream and is accelerated to approximately the speed of the waterjet stream. This step does steal some energy from the waterjet stream, slowing it down slightly.'),(191344,6972,'_content_blocks_11_description','field_6170d8cd9800c'),(191345,6972,'content_blocks_11_images',''),(191346,6972,'_content_blocks_11_images','field_6170d8df9800d'),(191347,6972,'content_blocks_12_header','5 - Accelerated Erosion'),(191348,6972,'_content_blocks_12_header','field_6170d8ba9800b'),(191349,6972,'content_blocks_12_description','The abrasive waterjet stream exits the mixing tube with extreme speed and power. The abrasive erodes the material to be cut. The process is referred to as \"abrasive waterjet cutting\" because it is the abrasive that is actually doing the cutting. The water\'s role is simply to give speed and power to the abrasive. In pure waterjet cutting, used for soft materials like foam and food, the force of the waterjet stream alone is enough to cut the material and abrasive is not required.'),(191350,6972,'_content_blocks_12_description','field_6170d8cd9800c'),(191351,6972,'content_blocks_12_images',''),(191352,6972,'_content_blocks_12_images','field_6170d8df9800d'),(191353,6972,'content_blocks_13_header','Affect of speed upon kerf angle'),(191354,6972,'_content_blocks_13_header','field_6170d8ba9800b'),(191355,6972,'content_blocks_13_description','Kerf angle, or bevel, refers to the dimensional difference between the top and bottom of the cut cross-section. Cutting too fast will result in a wider kerf width at the top of the cut cross-section and a narrower kerf width at the bottom of the zone. In Fig. 3, from left to right, cuts were done at 26 inches per minute (ipm), 14 ipm and 9.7 ipm (660 millimeters per minute [mm/min], 355 mm/min and 246 mm/min). All other parameters were held constant (pressure 60 kpsi, 0.060\" standoff distance, 1.3 lb/min abrasive [4134 bar, 1.5mm and 600 grams/min]). At the top of the cut, kerf width was similar, around 0.044\" (1.12 mm). The difference between top and bottom going from left to right was 0.017\", 0.013\" and 0.011\" (0.43 mm, 0.33 mm and 0.28 mm). This shows the decrease in angularity as speed decreases.\r\n\r\nFigure 3 - 3/4\" (20 mm) Aluminum with 3 different cut speeds'),(191356,6972,'_content_blocks_13_description','field_6170d8cd9800c'),(191357,6972,'content_blocks_13_images_0_image','2832'),(191358,6972,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(191359,6972,'content_blocks_13_images_0_header','High Speed, Widest Kerf at Top, Narrowest aat Bottom'),(191360,6972,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(191361,6972,'content_blocks_13_images_0_description',''),(191362,6972,'_content_blocks_13_images_0_description','field_6170d90398010'),(191363,6972,'content_blocks_13_images_1_image','2833'),(191364,6972,'_content_blocks_13_images_1_image','field_6170d8e99800e'),(191365,6972,'content_blocks_13_images_1_header','Medium Speed, Wider Kerf width at top than at bottom'),(191366,6972,'_content_blocks_13_images_1_header','field_6170d8f49800f'),(191367,6972,'content_blocks_13_images_1_description',''),(191368,6972,'_content_blocks_13_images_1_description','field_6170d90398010'),(191369,6972,'content_blocks_13_images_2_image','2834'),(191370,6972,'_content_blocks_13_images_2_image','field_6170d8e99800e'),(191371,6972,'content_blocks_13_images_2_header','Slower Speed, Similar width Kerf at top and bottom'),(191372,6972,'_content_blocks_13_images_2_header','field_6170d8f49800f'),(191373,6972,'content_blocks_13_images_2_description',''),(191374,6972,'_content_blocks_13_images_2_description','field_6170d90398010'),(191375,6972,'content_blocks_13_images','3'),(191376,6972,'_content_blocks_13_images','field_6170d8df9800d'),(191377,6972,'content_blocks_14_header',''),(191378,6972,'_content_blocks_14_header','field_6170d8ba9800b'),(191379,6972,'content_blocks_14_description','The picture below shows one additional cut that was done extremely slowly (1 ipm or 25.4 mm/min) to demonstrate that when speed is decreased enough, the kerf width at the bottom of the part will be larger than at the top. In this example the kerf width at the bottom was 0.014\" (0.36 mm) larger than at the top.'),(191380,6972,'_content_blocks_14_description','field_6170d8cd9800c'),(191381,6972,'content_blocks_14_images_0_image','2835'),(191382,6972,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(191383,6972,'content_blocks_14_images_0_header','Very slow speed, Narrower kerf width at top, Wider at Bottom'),(191384,6972,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(191385,6972,'content_blocks_14_images_0_description',''),(191386,6972,'_content_blocks_14_images_0_description','field_6170d90398010'),(191387,6972,'content_blocks_14_images','1'),(191388,6972,'_content_blocks_14_images','field_6170d8df9800d'),(191389,6972,'content_blocks','22'),(191390,6972,'_content_blocks','field_6170d8ac9800a'),(191391,6972,'menu','37'),(191392,6972,'_menu','field_6170d9e059837'),(191393,6972,'display_left_column','1'),(191394,6972,'_display_left_column','field_613563c4d424b'),(191395,6972,'contact_left_heading',''),(191396,6972,'_contact_left_heading','field_60c249d645c99'),(191397,6972,'contact_left_copy',''),(191398,6972,'_contact_left_copy','field_60c24a0845c9c'),(191399,6972,'display_right_column','1'),(191400,6972,'_display_right_column','field_613563f4d424c'),(191401,6972,'contact_right_heading',''),(191402,6972,'_contact_right_heading','field_60c249e945c9a'),(191403,6972,'contact_right_copy',''),(191404,6972,'_contact_right_copy','field_60c249f845c9b'),(191405,6972,'contact_right_cta',''),(191406,6972,'_contact_right_cta','field_60c24a1945c9d'),(191407,6972,'content_blocks_15_header','Drag of waterjet stream and cut quality'),(191408,6972,'_content_blocks_15_header','field_6170d8ba9800b'),(191409,6972,'content_blocks_15_description','Increasing feedrate results in increased trail back of waterjet stream. This concept is shown in Figure 5 below. Rougher edge quality is the result of more shearing action versus erosion action of abrasive at slower speeds. Modern controllers allow the user to adjust cut quality based upon part requirements. High-precision holes can be cut slower for a smoother, straighter cut. Faster cutting speeds with rougher edge quality can be used on less critical areas.'),(191410,6972,'_content_blocks_15_description','field_6170d8cd9800c'),(191411,6972,'content_blocks_15_images_0_image','2950'),(191412,6972,'_content_blocks_15_images_0_image','field_6170d8e99800e'),(191413,6972,'content_blocks_15_images_0_header','Seperation Cut'),(191414,6972,'_content_blocks_15_images_0_header','field_6170d8f49800f'),(191415,6972,'content_blocks_15_images_0_description',''),(191416,6972,'_content_blocks_15_images_0_description','field_6170d90398010'),(191417,6972,'content_blocks_15_images_1_image','2951'),(191418,6972,'_content_blocks_15_images_1_image','field_6170d8e99800e'),(191419,6972,'content_blocks_15_images_1_header','Through Cut'),(191420,6972,'_content_blocks_15_images_1_header','field_6170d8f49800f'),(191421,6972,'content_blocks_15_images_1_description',''),(191422,6972,'_content_blocks_15_images_1_description','field_6170d90398010'),(191423,6972,'content_blocks_15_images_2_image','2952'),(191424,6972,'_content_blocks_15_images_2_image','field_6170d8e99800e'),(191425,6972,'content_blocks_15_images_2_header','Clean Cut ± 0.010\"'),(191426,6972,'_content_blocks_15_images_2_header','field_6170d8f49800f'),(191427,6972,'content_blocks_15_images_2_description',''),(191428,6972,'_content_blocks_15_images_2_description','field_6170d90398010'),(191429,6972,'content_blocks_15_images_3_image','2953'),(191430,6972,'_content_blocks_15_images_3_image','field_6170d8e99800e'),(191431,6972,'content_blocks_15_images_3_header','Good Finish'),(191432,6972,'_content_blocks_15_images_3_header','field_6170d8f49800f'),(191433,6972,'content_blocks_15_images_3_description',''),(191434,6972,'_content_blocks_15_images_3_description','field_6170d90398010'),(191435,6972,'content_blocks_15_images_4_image','2954'),(191436,6972,'_content_blocks_15_images_4_image','field_6170d8e99800e'),(191437,6972,'content_blocks_15_images_4_header','Excellent Finish ± 0.005\"'),(191438,6972,'_content_blocks_15_images_4_header','field_6170d8f49800f'),(191439,6972,'content_blocks_15_images_4_description',''),(191440,6972,'_content_blocks_15_images_4_description','field_6170d90398010'),(191441,6972,'content_blocks_15_images','5'),(191442,6972,'_content_blocks_15_images','field_6170d8df9800d'),(191443,6972,'content_blocks_16_header','Effect of Nozzle Height'),(191444,6972,'_content_blocks_16_header','field_6170d8ba9800b'),(191445,6972,'content_blocks_16_description','For best cut quality, an optimum distance between the nozzle and the work piece should be maintained. Typically, between 0.0625\" and 0.125\" (1.5 – 3.0 mm) is the optimum height for abrasive waterjet cutting. As the distance increases above 0.125\", rounding on the top edge of the cut will result. This occurs because the waterjet stream looses coherence as it travels through open air. Increased nozzle height will also result in increased kerf angle. If the distance between the nozzle and the work piece is increased by ¼\", cutting speeds must be reduced by approximately 20% to achieve similar results with respect to tolerance and edge quality. Automatic height control is the most reliable and accurate way to maintain proper standoff distance. Figure 7 shows that if the nozzle height is increased too far, the jet will not have enough power to fully penetrate material that it would easily cut at much lower heights.'),(191446,6972,'_content_blocks_16_description','field_6170d8cd9800c'),(191447,6972,'content_blocks_16_images_0_image','2838'),(191448,6972,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(191449,6972,'content_blocks_16_images_0_header',''),(191450,6972,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(191451,6972,'content_blocks_16_images_0_description','Figure 6 - 3/4\" Aluminum with cuts at various nozzle heights, same speed'),(191452,6972,'_content_blocks_16_images_0_description','field_6170d90398010'),(191453,6972,'content_blocks_16_images_1_image','2839'),(191454,6972,'_content_blocks_16_images_1_image','field_6170d8e99800e'),(191455,6972,'content_blocks_16_images_1_header',''),(191456,6972,'_content_blocks_16_images_1_header','field_6170d8f49800f'),(191457,6972,'content_blocks_16_images_1_description','Figure 7 - Increasing nozzle height to point of no jet penetration'),(191458,6972,'_content_blocks_16_images_1_description','field_6170d90398010'),(191459,6972,'content_blocks_16_images','2'),(191460,6972,'_content_blocks_16_images','field_6170d8df9800d'),(191461,6972,'content_blocks_17_header','Effect of speed on inside corners'),(191462,6972,'_content_blocks_17_header','field_6170d8ba9800b'),(191463,6972,'content_blocks_17_description','Since the waterjet is a non-rigid cutting tool, inside corners on parts can exhibit a certain amount of overcut on the bottom, or exit, side of the part. This can be reduced by decelerating into the corner and slowly accelerating, allowing the bottom portion of the jet to catch up with the top portion around the corner. The waterjet control must have the ability to do this automatically.'),(191464,6972,'_content_blocks_17_description','field_6170d8cd9800c'),(191465,6972,'content_blocks_17_images_0_image','6963'),(191466,6972,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(191467,6972,'content_blocks_17_images_0_header',''),(191468,6972,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(191469,6972,'content_blocks_17_images_0_description','Figure 8 - Corner speed too fast'),(191470,6972,'_content_blocks_17_images_0_description','field_6170d90398010'),(191471,6972,'content_blocks_17_images','1'),(191472,6972,'_content_blocks_17_images','field_6170d8df9800d'),(191473,6972,'content_blocks_18_header','Tight radii'),(191474,6972,'_content_blocks_18_header','field_6170d8ba9800b'),(191475,6972,'content_blocks_18_description','Since the waterjet stream is a round tool, with a diameter between 0.030\" and 0.040\" (0.76 mm and 1.02 mm) for abrasive waterjet cutting, creating any inside corner that is perfectly square is impossible. CAM software will typically read geometries and give a user the option to automatically place a very small radius on these corners. This will avoid damaging the part and reduce processing time, as radii are faster to cut than square corners. For very acute angles, the actual part that is cut may differ significantly from the original drawing and should be considered for form, fit and function before processing.'),(191476,6972,'_content_blocks_18_description','field_6170d8cd9800c'),(191477,6972,'content_blocks_18_images_0_image','2840'),(191478,6972,'_content_blocks_18_images_0_image','field_6170d8e99800e'),(191479,6972,'content_blocks_18_images_0_header',''),(191480,6972,'_content_blocks_18_images_0_header','field_6170d8f49800f'),(191481,6972,'content_blocks_18_images_0_description',''),(191482,6972,'_content_blocks_18_images_0_description','field_6170d90398010'),(191483,6972,'content_blocks_18_images','1'),(191484,6972,'_content_blocks_18_images','field_6170d8df9800d'),(191485,6972,'content_blocks_19_header','Lead-in and Lead-out types'),(191486,6972,'_content_blocks_19_header','field_6170d8ba9800b'),(191487,6972,'content_blocks_19_description','Piercing in the scrap area of material and \"leading-in\" to the actual geometry to cut is standard operating procedure in most waterjet applications. This avoids placing a large blow-out blemish from the initial piercing on the surface of the part. At the end of a cut, a lead-out may be required to remove any \"nib\" from the lead-in area.\r\n\r\nVarious types of lead-ins and lead-outs can be experimented with for different materials and thicknesses. Figure 9 shows a few examples of lead-ins and leads-outs.'),(191488,6972,'_content_blocks_19_description','field_6170d8cd9800c'),(191489,6972,'content_blocks_19_images_0_image','2842'),(191490,6972,'_content_blocks_19_images_0_image','field_6170d8e99800e'),(191491,6972,'content_blocks_19_images_0_header','Different lead-in/lead-out types'),(191492,6972,'_content_blocks_19_images_0_header','field_6170d8f49800f'),(191493,6972,'content_blocks_19_images_0_description','Number 1 (straight line lead-in with very short straight line lead-out) is desirable for any sharp corner.\r\n\r\nNumber 2 (arc lead-in with short arc lead-out) is good for thinner and softer materials.\r\n\r\nNumber 3 (straight line lead in with no lead-out) gives good results on thicker, harder material.\r\n\r\nNumber 4 is an example of a straight line lead in with short arc lead-out. CAM software should have the flexibility to combine different types of lead-ins and lead-outs should the user wish to experiment.'),(191494,6972,'_content_blocks_19_images_0_description','field_6170d90398010'),(191495,6972,'content_blocks_19_images','1'),(191496,6972,'_content_blocks_19_images','field_6170d8df9800d'),(191497,6972,'content_blocks_20_header','Reducing lead-in/lead-out witness marks'),(191498,6972,'_content_blocks_20_header','field_6170d8ba9800b'),(191499,6972,'content_blocks_20_description','At the end of a cut, a small nib may remain on the bottom portion of the cut in the lead-in/lead-out area. Because of the lagging effect discussed previously, when the jet reaches the end of the cut, the top portion of the jet will find the path of least resistance, and effectively \"jump over\" a small bit of material leaving a nib. With the more sophisticated controls and software available today, this can be reduced by decelerating at the end of the cut to allow the bottom portion of the jet to catch up with the top before reaching the end of the cut. Figure 10 below shows examples of a large nib because of too much speed at the end of a cut and an example of a minimal witness mark with appropriate slow down at the end of the cut.'),(191500,6972,'_content_blocks_20_description','field_6170d8cd9800c'),(191501,6972,'content_blocks_20_images_0_image','2843'),(191502,6972,'_content_blocks_20_images_0_image','field_6170d8e99800e'),(191503,6972,'content_blocks_20_images_0_header',''),(191504,6972,'_content_blocks_20_images_0_header','field_6170d8f49800f'),(191505,6972,'content_blocks_20_images_0_description','Figure 10 - Bad part on left showing excessive nib'),(191506,6972,'_content_blocks_20_images_0_description','field_6170d90398010'),(191507,6972,'content_blocks_20_images_1_image','2844'),(191508,6972,'_content_blocks_20_images_1_image','field_6170d8e99800e'),(191509,6972,'content_blocks_20_images_1_header',''),(191510,6972,'_content_blocks_20_images_1_header','field_6170d8f49800f'),(191511,6972,'content_blocks_20_images_1_description','Good part on right with minimal witness mark'),(191512,6972,'_content_blocks_20_images_1_description','field_6170d90398010'),(191513,6972,'content_blocks_20_images','2'),(191514,6972,'_content_blocks_20_images','field_6170d8df9800d'),(191515,6972,'content_blocks_21_header','Waterjet stream\'s effect on accuracy'),(191516,6972,'_content_blocks_21_header','field_6170d8ba9800b'),(191517,6972,'content_blocks_21_description','Mixing tubes are made of extremely hard materials such as sintered boride or more commonly composite tungsten carbide. However, the nozzles are subject to wear and their cost must be taken into consideration for job costing. The orifice of a mixing tube will typically increase in diameter by about 0.0001\" per hour of cutting because of the erosion of the abrasive flowing through the nozzle. If this wear occurs in an even fashion, up to 120 hours of cutting can be realized with a nozzle. The biggest factor affecting nozzle wear is the material from which they are made. Controls allow for compensating for this wear by allowing the operator to change the tool offset.\r\n\r\n<img class=\"alignnone size-full wp-image-6967\" src=\"http://www.wardjet.com/wp-content/uploads/2022/03/new-mixing-tube.jpg\" alt=\"new mixing tube\" width=\"280\" /> <img class=\"alignnone size-full wp-image-6966\" src=\"http://www.wardjet.com/wp-content/uploads/2022/03/used-mixing-tube.jpg\" alt=\"\" width=\"280\" />\r\n\r\n<span style=\"color: #808080;\"><em>Figure 11 - New and used mixing tubes. Note orifice on right is off-center.</em></span>\r\n\r\nIf the wear of the nozzle is not symmetrical, the waterjet stream will also not be round. This will result in wider tolerances when cutting in a certain direction.\r\n\r\nThe tolerance requirements of a job will dictate the actual number of hours a user can expect from a nozzle. The nozzle can, of course, be set aside and used later for looser tolerance jobs. Control software should allow the ability to track hours on individual components to make consumable management easier. See Figure 12 below for an example of orifice and mixing tube tracking.'),(191518,6972,'_content_blocks_21_description','field_6170d8cd9800c'),(191519,6972,'content_blocks_21_images',''),(191520,6972,'_content_blocks_21_images','field_6170d8df9800d'),(191522,3569,'content_blocks_1_images',''),(191523,3468,'content_blocks_1_images',''),(191524,6973,'_wp_attached_file','2022/03/closeup-of-waterjet-cutting-head.jpg'),(191525,6973,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:509;s:6:\"height\";i:381;s:4:\"file\";s:44:\"2022/03/closeup-of-waterjet-cutting-head.jpg\";s:5:\"sizes\";a:2:{s:6:\"medium\";a:4:{s:4:\"file\";s:44:\"closeup-of-waterjet-cutting-head-300x225.jpg\";s:5:\"width\";i:300;s:6:\"height\";i:225;s:9:\"mime-type\";s:10:\"image/jpeg\";}s:9:\"thumbnail\";a:4:{s:4:\"file\";s:44:\"closeup-of-waterjet-cutting-head-150x150.jpg\";s:5:\"width\";i:150;s:6:\"height\";i:150;s:9:\"mime-type\";s:10:\"image/jpeg\";}}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(191526,6973,'_wp_attachment_image_alt','closeup-of-waterjet-cutting-head'),(191527,2829,'rank_math_description','This chapter will focus on the cutting head and the waterjet as it interacts with the work piece.'),(191528,2829,'rank_math_focus_keyword','precision and quality'),(191529,6973,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2829;}}'),(191530,6974,'hero_gallery',''),(191531,6974,'_hero_gallery','field_60c23d554e4a3'),(191532,6974,'hero_banner','6932'),(191533,6974,'_hero_banner','field_6170dbe179470'),(191534,6974,'page_title','Precision and Quality'),(191535,6974,'_page_title','field_6170d88998008'),(191536,6974,'page_description',''),(191537,6974,'_page_description','field_6170d89398009'),(191538,6974,'content_blocks_0_header','Overview'),(191539,6974,'_content_blocks_0_header','field_6170d8ba9800b'),(191540,6974,'content_blocks_0_description','For successful abrasive waterjet cutting, there are several factors at the cutting head that determine the precision and quality of the waterjet stream and will affect the quality of part you are able to cut with an abrasive waterjet. There are other factors that will go into cutting a precise and accurate part (machine design, controls, software and high-pressure pump) that will be discussed in other chapters. This chapter will focus on the cutting head and the waterjet as it interacts with the work piece.'),(191541,6974,'_content_blocks_0_description','field_6170d8cd9800c'),(191542,6974,'content_blocks_0_images',''),(191543,6974,'_content_blocks_0_images','field_6170d8df9800d'),(191544,6974,'content_blocks_1_header','Factors affecting precision & quality'),(191545,6974,'_content_blocks_1_header','field_6170d8ba9800b'),(191546,6974,'content_blocks_1_description','<img class=\"alignnone size-medium wp-image-6971\" src=\"http://www.wardjet.com/wp-content/uploads/2022/03/Factors-affecting-precision-quality-1-300x274.jpg\" alt=\"Factors affecting precision &amp; quality 1\" width=\"300\" height=\"274\" /><img class=\"alignnone size-medium wp-image-6970\" src=\"http://www.wardjet.com/wp-content/uploads/2022/03/Factors-affecting-precision-quality-2-300x295.jpg\" alt=\"\" width=\"300\" height=\"295\" />\r\n\r\n<span style=\"color: #808080;\"><em>Figure 1 - Abrasive and Water Only Waterjet Cutting Heads</em></span>'),(191547,6974,'_content_blocks_1_description','field_6170d8cd9800c'),(191548,6974,'content_blocks_1_images',''),(191549,6974,'_content_blocks_1_images','field_6170d8df9800d'),(191550,6974,'content_blocks_2_header','1 - Abrasive mixing tube length'),(191551,6974,'_content_blocks_2_header','field_6170d8ba9800b'),(191552,6974,'content_blocks_2_description','A longer abrasive mixing tube (a.k.a. abrasive nozzle) produces a more coherent waterjet stream. The optimum mixing tube length is 3\" - 4\" (75 mm - 100 mm).'),(191553,6974,'_content_blocks_2_description','field_6170d8cd9800c'),(191554,6974,'content_blocks_2_images',''),(191555,6974,'_content_blocks_2_images','field_6170d8df9800d'),(191556,6974,'content_blocks_3_header','2 - Alignment of components'),(191557,6974,'_content_blocks_3_header','field_6170d8ba9800b'),(191558,6974,'content_blocks_3_description','The orifice, mixing chamber and abrasive nozzle must be precisely machined and fit perfectly together to avoid damage of consumables by the waterjet stream.'),(191559,6974,'_content_blocks_3_description','field_6170d8cd9800c'),(191560,6974,'content_blocks_3_images',''),(191561,6974,'_content_blocks_3_images','field_6170d8df9800d'),(191562,6974,'content_blocks_4_header','3 - Precise orifice'),(191563,6974,'_content_blocks_4_header','field_6170d8ba9800b'),(191564,6974,'content_blocks_4_description','The inside of the abrasive nozzle must be machined to ensure perfect alignment with the waterjet stream. See \"Waterjet stream\'s effect on accuracy\" section of this chapter for more information.'),(191565,6974,'_content_blocks_4_description','field_6170d8cd9800c'),(191566,6974,'content_blocks_4_images',''),(191567,6974,'_content_blocks_4_images','field_6170d8df9800d'),(191568,6974,'content_blocks_5_header','4 - Diameter of stream'),(191569,6974,'_content_blocks_5_header','field_6170d8ba9800b'),(191570,6974,'content_blocks_5_description','A small diameter waterjet stream, as produced by a .010\" (0.25 mm) orifice produces an efficient, high-quality stream. As a trade-off, cutting speeds are slower than when using a 0.014\" (0.36 mm) or larger orifice, since less water and abrasive are used. See Chapter 2 \"Relationship Parameters\" for more information on orifice selection.'),(191571,6974,'_content_blocks_5_description','field_6170d8cd9800c'),(191572,6974,'content_blocks_5_images',''),(191573,6974,'_content_blocks_5_images','field_6170d8df9800d'),(191574,6974,'content_blocks_6_header','5 - Low, controlled stand-off from work'),(191575,6974,'_content_blocks_6_header','field_6170d8ba9800b'),(191576,6974,'content_blocks_6_description','Maintaining a close distance between the nozzle and the work piece, between 0.040\" and 0.060\" (1.0 - 1.5 mm), is critical for producing accurate parts while also getting the maximum efficiency from the waterjet. Cutting closer to the material limits the amount of atmosphere that the jet has to travel through before reaching the work piece. This limits the expansion of the waterjet stream, since as the jet expands, the effective power of the jet is reduced. Cutting speeds will need to be reduced to compensate. If the distance between the nozzle and the work piece is increased by ¼\", cutting speeds must be reduced by approximately 20% to achieve similar results with respect to tolerance and edge quality. Cutting under water with CNC height control will allow for ultimate control of the waterjet stream.\r\n\r\nSee effect of nozzle height below for more information.'),(191577,6974,'_content_blocks_6_description','field_6170d8cd9800c'),(191578,6974,'content_blocks_6_images',''),(191579,6974,'_content_blocks_6_images','field_6170d8df9800d'),(191580,6974,'content_blocks_7_header','Creation of the abrasive waterjet stream'),(191581,6974,'_content_blocks_7_header','field_6170d8ba9800b'),(191582,6974,'content_blocks_7_description','Following is a description of how the abrasive waterjet stream is created in the cutting head. The numbers indicated below refer to the numbers in Figure 2.\r\n\r\n<img class=\"alignnone size-medium wp-image-6973\" src=\"http://www.wardjet.com/wp-content/uploads/2022/03/closeup-of-waterjet-cutting-head-300x225.jpg\" alt=\"closeup-of-waterjet-cutting-head\" width=\"300\" height=\"225\" />\r\n\r\n<span style=\"color: #808080;\"><em>Figure 2 - Close-up of the abrasive waterjet cutting head</em></span>'),(191583,6974,'_content_blocks_7_description','field_6170d8cd9800c'),(191584,6974,'content_blocks_7_images',''),(191585,6974,'_content_blocks_7_images','field_6170d8df9800d'),(191586,6974,'content_blocks_8_header','1 - Water Pressure'),(191587,6974,'_content_blocks_8_header','field_6170d8ba9800b'),(191588,6974,'content_blocks_8_description','Water pressurized at 50,000 psi or greater enters the cutting head at relatively slow speed, in the order of a few feet per second. (See \"How It Works\" for more information on how this water pressure is created and transmitted to the cutting head.)'),(191589,6974,'_content_blocks_8_description','field_6170d8cd9800c'),(191590,6974,'content_blocks_8_images',''),(191591,6974,'_content_blocks_8_images','field_6170d8df9800d'),(191592,6974,'content_blocks_9_header','Stream Conversion'),(191593,6974,'_content_blocks_9_header','field_6170d8ba9800b'),(191594,6974,'content_blocks_9_description','The water is forced through an orifice that has a small diameter orifice, anywhere from 0.004\" to 0.045\" depending upon the application. These orifices are made of extremely hard material, such as diamond, sapphire or ruby. This step converts the water stream from a high pressure stream to a high velocity stream. At this point the water is moving in excess of 2200 miles per hour (3657 kilometers per hour).'),(191595,6974,'_content_blocks_9_description','field_6170d8cd9800c'),(191596,6974,'content_blocks_9_images',''),(191597,6974,'_content_blocks_9_images','field_6170d8df9800d'),(191598,6974,'content_blocks_10_header','3 - Venturi Effect'),(191599,6974,'_content_blocks_10_header','field_6170d8ba9800b'),(191600,6974,'content_blocks_10_description','The high velocity of the jet creates a Venturi effect, or vacuum, in the mixing chamber located immediately beneath the orifice. Abrasive, typically garnet, is metered from a mini-hopper through a plastic tube down to the cutting head and is sucked into the waterjet stream in the mixing chamber. Cutting speed will increase with more abrasive until a saturation point is reached where speed starts to decrease. If the abrasive amount is increased too high, ultimately the mixing tube will clog.\r\nOne of the exciting advancements in waterjet cutting in the past few years is the appearance on CNC- controlled abrasive metering systems. These systems precisely control the amount of abrasive that is allowed to flow to the cutting head. During the piercing process, cutting pressure and abrasive amount are reduced and the cutting head makes small, circular motions in the X and Y axes. This piercing procedure allows for difficult applications, such as piercing of glass and stone, to be processed with relative ease.'),(191601,6974,'_content_blocks_10_description','field_6170d8cd9800c'),(191602,6974,'content_blocks_10_images',''),(191603,6974,'_content_blocks_10_images','field_6170d8df9800d'),(191604,6974,'content_blocks_11_header','4 - Waterjet stream & abrasive mixture'),(191605,6974,'_content_blocks_11_header','field_6170d8ba9800b'),(191606,6974,'content_blocks_11_description','The abrasive is fully mixed in the waterjet stream and is accelerated to approximately the speed of the waterjet stream. This step does steal some energy from the waterjet stream, slowing it down slightly.'),(191607,6974,'_content_blocks_11_description','field_6170d8cd9800c'),(191608,6974,'content_blocks_11_images',''),(191609,6974,'_content_blocks_11_images','field_6170d8df9800d'),(191610,6974,'content_blocks_12_header','5 - Accelerated Erosion'),(191611,6974,'_content_blocks_12_header','field_6170d8ba9800b'),(191612,6974,'content_blocks_12_description','The abrasive waterjet stream exits the mixing tube with extreme speed and power. The abrasive erodes the material to be cut. The process is referred to as \"abrasive waterjet cutting\" because it is the abrasive that is actually doing the cutting. The water\'s role is simply to give speed and power to the abrasive. In pure waterjet cutting, used for soft materials like foam and food, the force of the waterjet stream alone is enough to cut the material and abrasive is not required.'),(191613,6974,'_content_blocks_12_description','field_6170d8cd9800c'),(191614,6974,'content_blocks_12_images',''),(191615,6974,'_content_blocks_12_images','field_6170d8df9800d'),(191616,6974,'content_blocks_13_header','Affect of speed upon kerf angle'),(191617,6974,'_content_blocks_13_header','field_6170d8ba9800b'),(191618,6974,'content_blocks_13_description','Kerf angle, or bevel, refers to the dimensional difference between the top and bottom of the cut cross-section. Cutting too fast will result in a wider kerf width at the top of the cut cross-section and a narrower kerf width at the bottom of the zone. In Fig. 3, from left to right, cuts were done at 26 inches per minute (ipm), 14 ipm and 9.7 ipm (660 millimeters per minute [mm/min], 355 mm/min and 246 mm/min). All other parameters were held constant (pressure 60 kpsi, 0.060\" standoff distance, 1.3 lb/min abrasive [4134 bar, 1.5mm and 600 grams/min]). At the top of the cut, kerf width was similar, around 0.044\" (1.12 mm). The difference between top and bottom going from left to right was 0.017\", 0.013\" and 0.011\" (0.43 mm, 0.33 mm and 0.28 mm). This shows the decrease in angularity as speed decreases.\r\n\r\nFigure 3 - 3/4\" (20 mm) Aluminum with 3 different cut speeds'),(191619,6974,'_content_blocks_13_description','field_6170d8cd9800c'),(191620,6974,'content_blocks_13_images_0_image','2832'),(191621,6974,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(191622,6974,'content_blocks_13_images_0_header','High Speed, Widest Kerf at Top, Narrowest aat Bottom'),(191623,6974,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(191624,6974,'content_blocks_13_images_0_description',''),(191625,6974,'_content_blocks_13_images_0_description','field_6170d90398010'),(191626,6974,'content_blocks_13_images_1_image','2833'),(191627,6974,'_content_blocks_13_images_1_image','field_6170d8e99800e'),(191628,6974,'content_blocks_13_images_1_header','Medium Speed, Wider Kerf width at top than at bottom'),(191629,6974,'_content_blocks_13_images_1_header','field_6170d8f49800f'),(191630,6974,'content_blocks_13_images_1_description',''),(191631,6974,'_content_blocks_13_images_1_description','field_6170d90398010'),(191632,6974,'content_blocks_13_images_2_image','2834'),(191633,6974,'_content_blocks_13_images_2_image','field_6170d8e99800e'),(191634,6974,'content_blocks_13_images_2_header','Slower Speed, Similar width Kerf at top and bottom'),(191635,6974,'_content_blocks_13_images_2_header','field_6170d8f49800f'),(191636,6974,'content_blocks_13_images_2_description',''),(191637,6974,'_content_blocks_13_images_2_description','field_6170d90398010'),(191638,6974,'content_blocks_13_images','3'),(191639,6974,'_content_blocks_13_images','field_6170d8df9800d'),(191640,6974,'content_blocks_14_header',''),(191641,6974,'_content_blocks_14_header','field_6170d8ba9800b'),(191642,6974,'content_blocks_14_description','The picture below shows one additional cut that was done extremely slowly (1 ipm or 25.4 mm/min) to demonstrate that when speed is decreased enough, the kerf width at the bottom of the part will be larger than at the top. In this example the kerf width at the bottom was 0.014\" (0.36 mm) larger than at the top.'),(191643,6974,'_content_blocks_14_description','field_6170d8cd9800c'),(191644,6974,'content_blocks_14_images_0_image','2835'),(191645,6974,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(191646,6974,'content_blocks_14_images_0_header','Very slow speed, Narrower kerf width at top, Wider at Bottom.'),(191647,6974,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(191648,6974,'content_blocks_14_images_0_description',''),(191649,6974,'_content_blocks_14_images_0_description','field_6170d90398010'),(191650,6974,'content_blocks_14_images','1'),(191651,6974,'_content_blocks_14_images','field_6170d8df9800d'),(191652,6974,'content_blocks','22'),(191653,6974,'_content_blocks','field_6170d8ac9800a'),(191654,6974,'menu','37'),(191655,6974,'_menu','field_6170d9e059837'),(191656,6974,'display_left_column','1'),(191657,6974,'_display_left_column','field_613563c4d424b'),(191658,6974,'contact_left_heading',''),(191659,6974,'_contact_left_heading','field_60c249d645c99'),(191660,6974,'contact_left_copy',''),(191661,6974,'_contact_left_copy','field_60c24a0845c9c'),(191662,6974,'display_right_column','1'),(191663,6974,'_display_right_column','field_613563f4d424c'),(191664,6974,'contact_right_heading',''),(191665,6974,'_contact_right_heading','field_60c249e945c9a'),(191666,6974,'contact_right_copy',''),(191667,6974,'_contact_right_copy','field_60c249f845c9b'),(191668,6974,'contact_right_cta',''),(191669,6974,'_contact_right_cta','field_60c24a1945c9d'),(191670,6974,'content_blocks_15_header','Drag of waterjet stream and cut quality'),(191671,6974,'_content_blocks_15_header','field_6170d8ba9800b'),(191672,6974,'content_blocks_15_description','Increasing feedrate results in increased trail back of waterjet stream. This concept is shown in Figure 5 below. Rougher edge quality is the result of more shearing action versus erosion action of abrasive at slower speeds. Modern controllers allow the user to adjust cut quality based upon part requirements. High-precision holes can be cut slower for a smoother, straighter cut. Faster cutting speeds with rougher edge quality can be used on less critical areas.'),(191673,6974,'_content_blocks_15_description','field_6170d8cd9800c'),(191674,6974,'content_blocks_15_images_0_image','2950'),(191675,6974,'_content_blocks_15_images_0_image','field_6170d8e99800e'),(191676,6974,'content_blocks_15_images_0_header','Seperation Cut'),(191677,6974,'_content_blocks_15_images_0_header','field_6170d8f49800f'),(191678,6974,'content_blocks_15_images_0_description',''),(191679,6974,'_content_blocks_15_images_0_description','field_6170d90398010'),(191680,6974,'content_blocks_15_images_1_image','2951'),(191681,6974,'_content_blocks_15_images_1_image','field_6170d8e99800e'),(191682,6974,'content_blocks_15_images_1_header','Through Cut'),(191683,6974,'_content_blocks_15_images_1_header','field_6170d8f49800f'),(191684,6974,'content_blocks_15_images_1_description',''),(191685,6974,'_content_blocks_15_images_1_description','field_6170d90398010'),(191686,6974,'content_blocks_15_images_2_image','2952'),(191687,6974,'_content_blocks_15_images_2_image','field_6170d8e99800e'),(191688,6974,'content_blocks_15_images_2_header','Clean Cut ± 0.010\"'),(191689,6974,'_content_blocks_15_images_2_header','field_6170d8f49800f'),(191690,6974,'content_blocks_15_images_2_description',''),(191691,6974,'_content_blocks_15_images_2_description','field_6170d90398010'),(191692,6974,'content_blocks_15_images_3_image','2953'),(191693,6974,'_content_blocks_15_images_3_image','field_6170d8e99800e'),(191694,6974,'content_blocks_15_images_3_header','Good Finish'),(191695,6974,'_content_blocks_15_images_3_header','field_6170d8f49800f'),(191696,6974,'content_blocks_15_images_3_description',''),(191697,6974,'_content_blocks_15_images_3_description','field_6170d90398010'),(191698,6974,'content_blocks_15_images_4_image','2954'),(191699,6974,'_content_blocks_15_images_4_image','field_6170d8e99800e'),(191700,6974,'content_blocks_15_images_4_header','Excellent Finish ± 0.005\"'),(191701,6974,'_content_blocks_15_images_4_header','field_6170d8f49800f'),(191702,6974,'content_blocks_15_images_4_description',''),(191703,6974,'_content_blocks_15_images_4_description','field_6170d90398010'),(191704,6974,'content_blocks_15_images','5'),(191705,6974,'_content_blocks_15_images','field_6170d8df9800d'),(191706,6974,'content_blocks_16_header','Effect of Nozzle Height'),(191707,6974,'_content_blocks_16_header','field_6170d8ba9800b'),(191708,6974,'content_blocks_16_description','For best cut quality, an optimum distance between the nozzle and the work piece should be maintained. Typically, between 0.0625\" and 0.125\" (1.5 – 3.0 mm) is the optimum height for abrasive waterjet cutting. As the distance increases above 0.125\", rounding on the top edge of the cut will result. This occurs because the waterjet stream looses coherence as it travels through open air. Increased nozzle height will also result in increased kerf angle. If the distance between the nozzle and the work piece is increased by ¼\", cutting speeds must be reduced by approximately 20% to achieve similar results with respect to tolerance and edge quality. Automatic height control is the most reliable and accurate way to maintain proper standoff distance. Figure 7 shows that if the nozzle height is increased too far, the jet will not have enough power to fully penetrate material that it would easily cut at much lower heights.'),(191709,6974,'_content_blocks_16_description','field_6170d8cd9800c'),(191710,6974,'content_blocks_16_images_0_image','2838'),(191711,6974,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(191712,6974,'content_blocks_16_images_0_header',''),(191713,6974,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(191714,6974,'content_blocks_16_images_0_description','Figure 6 - 3/4\" Aluminum with cuts at various nozzle heights, same speed'),(191715,6974,'_content_blocks_16_images_0_description','field_6170d90398010'),(191716,6974,'content_blocks_16_images_1_image','2839'),(191717,6974,'_content_blocks_16_images_1_image','field_6170d8e99800e'),(191718,6974,'content_blocks_16_images_1_header',''),(191719,6974,'_content_blocks_16_images_1_header','field_6170d8f49800f'),(191720,6974,'content_blocks_16_images_1_description','Figure 7 - Increasing nozzle height to point of no jet penetration'),(191721,6974,'_content_blocks_16_images_1_description','field_6170d90398010'),(191722,6974,'content_blocks_16_images','2'),(191723,6974,'_content_blocks_16_images','field_6170d8df9800d'),(191724,6974,'content_blocks_17_header','Effect of speed on inside corners'),(191725,6974,'_content_blocks_17_header','field_6170d8ba9800b'),(191726,6974,'content_blocks_17_description','Since the waterjet is a non-rigid cutting tool, inside corners on parts can exhibit a certain amount of overcut on the bottom, or exit, side of the part. This can be reduced by decelerating into the corner and slowly accelerating, allowing the bottom portion of the jet to catch up with the top portion around the corner. The waterjet control must have the ability to do this automatically.'),(191727,6974,'_content_blocks_17_description','field_6170d8cd9800c'),(191728,6974,'content_blocks_17_images_0_image','6963'),(191729,6974,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(191730,6974,'content_blocks_17_images_0_header',''),(191731,6974,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(191732,6974,'content_blocks_17_images_0_description','Figure 8 - Corner speed too fast'),(191733,6974,'_content_blocks_17_images_0_description','field_6170d90398010'),(191734,6974,'content_blocks_17_images','1'),(191735,6974,'_content_blocks_17_images','field_6170d8df9800d'),(191736,6974,'content_blocks_18_header','Tight radii'),(191737,6974,'_content_blocks_18_header','field_6170d8ba9800b'),(191738,6974,'content_blocks_18_description','Since the waterjet stream is a round tool, with a diameter between 0.030\" and 0.040\" (0.76 mm and 1.02 mm) for abrasive waterjet cutting, creating any inside corner that is perfectly square is impossible. CAM software will typically read geometries and give a user the option to automatically place a very small radius on these corners. This will avoid damaging the part and reduce processing time, as radii are faster to cut than square corners. For very acute angles, the actual part that is cut may differ significantly from the original drawing and should be considered for form, fit and function before processing.'),(191739,6974,'_content_blocks_18_description','field_6170d8cd9800c'),(191740,6974,'content_blocks_18_images_0_image','2840'),(191741,6974,'_content_blocks_18_images_0_image','field_6170d8e99800e'),(191742,6974,'content_blocks_18_images_0_header',''),(191743,6974,'_content_blocks_18_images_0_header','field_6170d8f49800f'),(191744,6974,'content_blocks_18_images_0_description',''),(191745,6974,'_content_blocks_18_images_0_description','field_6170d90398010'),(191746,6974,'content_blocks_18_images','1'),(191747,6974,'_content_blocks_18_images','field_6170d8df9800d'),(191748,6974,'content_blocks_19_header','Lead-in and Lead-out types'),(191749,6974,'_content_blocks_19_header','field_6170d8ba9800b'),(191750,6974,'content_blocks_19_description','Piercing in the scrap area of material and \"leading-in\" to the actual geometry to cut is standard operating procedure in most waterjet applications. This avoids placing a large blow-out blemish from the initial piercing on the surface of the part. At the end of a cut, a lead-out may be required to remove any \"nib\" from the lead-in area.\r\n\r\nVarious types of lead-ins and lead-outs can be experimented with for different materials and thicknesses. Figure 9 shows a few examples of lead-ins and leads-outs.'),(191751,6974,'_content_blocks_19_description','field_6170d8cd9800c'),(191752,6974,'content_blocks_19_images_0_image','2842'),(191753,6974,'_content_blocks_19_images_0_image','field_6170d8e99800e'),(191754,6974,'content_blocks_19_images_0_header','Different lead-in/lead-out types'),(191755,6974,'_content_blocks_19_images_0_header','field_6170d8f49800f'),(191756,6974,'content_blocks_19_images_0_description','Number 1 (straight line lead-in with very short straight line lead-out) is desirable for any sharp corner.\r\n\r\nNumber 2 (arc lead-in with short arc lead-out) is good for thinner and softer materials.\r\n\r\nNumber 3 (straight line lead in with no lead-out) gives good results on thicker, harder material.\r\n\r\nNumber 4 is an example of a straight line lead in with short arc lead-out. CAM software should have the flexibility to combine different types of lead-ins and lead-outs should the user wish to experiment.'),(191757,6974,'_content_blocks_19_images_0_description','field_6170d90398010'),(191758,6974,'content_blocks_19_images','1'),(191759,6974,'_content_blocks_19_images','field_6170d8df9800d'),(191760,6974,'content_blocks_20_header','Reducing lead-in/lead-out witness marks'),(191761,6974,'_content_blocks_20_header','field_6170d8ba9800b'),(191762,6974,'content_blocks_20_description','At the end of a cut, a small nib may remain on the bottom portion of the cut in the lead-in/lead-out area. Because of the lagging effect discussed previously, when the jet reaches the end of the cut, the top portion of the jet will find the path of least resistance, and effectively \"jump over\" a small bit of material leaving a nib. With the more sophisticated controls and software available today, this can be reduced by decelerating at the end of the cut to allow the bottom portion of the jet to catch up with the top before reaching the end of the cut. Figure 10 below shows examples of a large nib because of too much speed at the end of a cut and an example of a minimal witness mark with appropriate slow down at the end of the cut.'),(191763,6974,'_content_blocks_20_description','field_6170d8cd9800c'),(191764,6974,'content_blocks_20_images_0_image','2843'),(191765,6974,'_content_blocks_20_images_0_image','field_6170d8e99800e'),(191766,6974,'content_blocks_20_images_0_header',''),(191767,6974,'_content_blocks_20_images_0_header','field_6170d8f49800f'),(191768,6974,'content_blocks_20_images_0_description','Figure 10 - Bad part on left showing excessive nib'),(191769,6974,'_content_blocks_20_images_0_description','field_6170d90398010'),(191770,6974,'content_blocks_20_images_1_image','2844'),(191771,6974,'_content_blocks_20_images_1_image','field_6170d8e99800e'),(191772,6974,'content_blocks_20_images_1_header',''),(191773,6974,'_content_blocks_20_images_1_header','field_6170d8f49800f'),(191774,6974,'content_blocks_20_images_1_description','Good part on right with minimal witness mark'),(191775,6974,'_content_blocks_20_images_1_description','field_6170d90398010'),(191776,6974,'content_blocks_20_images','2'),(191777,6974,'_content_blocks_20_images','field_6170d8df9800d'),(191778,6974,'content_blocks_21_header','Waterjet stream\'s effect on accuracy'),(191779,6974,'_content_blocks_21_header','field_6170d8ba9800b'),(191780,6974,'content_blocks_21_description','Mixing tubes are made of extremely hard materials such as sintered boride or more commonly composite tungsten carbide. However, the nozzles are subject to wear and their cost must be taken into consideration for job costing. The orifice of a mixing tube will typically increase in diameter by about 0.0001\" per hour of cutting because of the erosion of the abrasive flowing through the nozzle. If this wear occurs in an even fashion, up to 120 hours of cutting can be realized with a nozzle. The biggest factor affecting nozzle wear is the material from which they are made. Controls allow for compensating for this wear by allowing the operator to change the tool offset.\r\n\r\n<img class=\"alignnone size-full wp-image-6967\" src=\"http://www.wardjet.com/wp-content/uploads/2022/03/new-mixing-tube.jpg\" alt=\"new mixing tube\" width=\"280\" /> <img class=\"alignnone size-full wp-image-6966\" src=\"http://www.wardjet.com/wp-content/uploads/2022/03/used-mixing-tube.jpg\" alt=\"\" width=\"280\" />\r\n\r\n<span style=\"color: #808080;\"><em>Figure 11 - New and used mixing tubes. Note orifice on right is off-center.</em></span>\r\n\r\nIf the wear of the nozzle is not symmetrical, the waterjet stream will also not be round. This will result in wider tolerances when cutting in a certain direction.\r\n\r\nThe tolerance requirements of a job will dictate the actual number of hours a user can expect from a nozzle. The nozzle can, of course, be set aside and used later for looser tolerance jobs. Control software should allow the ability to track hours on individual components to make consumable management easier. See Figure 12 below for an example of orifice and mixing tube tracking.'),(191781,6974,'_content_blocks_21_description','field_6170d8cd9800c'),(191782,6974,'content_blocks_21_images',''),(191783,6974,'_content_blocks_21_images','field_6170d8df9800d'),(191784,2829,'_wpml_media_has_media','1'),(191785,3569,'content_blocks_7_images',''),(191786,3468,'content_blocks_7_images',''),(191787,2849,'_wp_attachment_image_alt','Waterjet University_Nozzle n Orifice Intensifier Pump Chart'),(191788,6975,'_wp_attached_file','2022/03/nozzle-and-orifice-direct-drive.jpg'),(191789,6975,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:469;s:6:\"height\";i:330;s:4:\"file\";s:43:\"2022/03/nozzle-and-orifice-direct-drive.jpg\";s:5:\"sizes\";a:2:{s:6:\"medium\";a:4:{s:4:\"file\";s:43:\"nozzle-and-orifice-direct-drive-300x211.jpg\";s:5:\"width\";i:300;s:6:\"height\";i:211;s:9:\"mime-type\";s:10:\"image/jpeg\";}s:9:\"thumbnail\";a:4:{s:4:\"file\";s:43:\"nozzle-and-orifice-direct-drive-150x150.jpg\";s:5:\"width\";i:150;s:6:\"height\";i:150;s:9:\"mime-type\";s:10:\"image/jpeg\";}}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(191790,6975,'_wp_attachment_image_alt',''),(191791,6975,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2848;}}'),(191792,6976,'hero_gallery',''),(191793,6976,'_hero_gallery','field_60c23d554e4a3'),(191794,6976,'hero_banner','6956'),(191795,6976,'_hero_banner','field_6170dbe179470'),(191796,6976,'page_title','Nozzle and Orifice'),(191797,6976,'_page_title','field_6170d88998008'),(191798,6976,'page_description','This section will focus on relationships between speed and edge quality, pump size, water nozzle and abrasive nozzle selection, maximum number of cutting heads and how some of these parameters can change over time.'),(191799,6976,'_page_description','field_6170d89398009'),(191800,6976,'content_blocks_0_header','Desired edge quality'),(191801,6976,'_content_blocks_0_header','field_6170d8ba9800b'),(191802,6976,'content_blocks_0_description','Edge quality is defined with the numbers 1 through 5. Lower numbers indicate rougher edge finish; higher numbers are smoother. For thin materials, the difference in cutting speed for Quality 1 could be as much as 3 times faster than the speed for Quality 5. For thicker materials, Quality 1 could be 6 times faster than Quality 5. For example, 4” thick Aluminum Q5 would be 0.72 ipm (18 mm/min) and Q1 would be 4.2 ipm (107 mm/min), 5.8 times faster.'),(191803,6976,'_content_blocks_0_description','field_6170d8cd9800c'),(191804,6976,'content_blocks_0_images_0_image','2950'),(191805,6976,'_content_blocks_0_images_0_image','field_6170d8e99800e'),(191806,6976,'content_blocks_0_images_0_header','Seperation Cut'),(191807,6976,'_content_blocks_0_images_0_header','field_6170d8f49800f'),(191808,6976,'content_blocks_0_images_0_description',''),(191809,6976,'_content_blocks_0_images_0_description','field_6170d90398010'),(191810,6976,'content_blocks_0_images_1_image','2951'),(191811,6976,'_content_blocks_0_images_1_image','field_6170d8e99800e'),(191812,6976,'content_blocks_0_images_1_header','Through Cut'),(191813,6976,'_content_blocks_0_images_1_header','field_6170d8f49800f'),(191814,6976,'content_blocks_0_images_1_description',''),(191815,6976,'_content_blocks_0_images_1_description','field_6170d90398010'),(191816,6976,'content_blocks_0_images_2_image','2952'),(191817,6976,'_content_blocks_0_images_2_image','field_6170d8e99800e'),(191818,6976,'content_blocks_0_images_2_header','Clean Cut ± 0.010\"'),(191819,6976,'_content_blocks_0_images_2_header','field_6170d8f49800f'),(191820,6976,'content_blocks_0_images_2_description',''),(191821,6976,'_content_blocks_0_images_2_description','field_6170d90398010'),(191822,6976,'content_blocks_0_images_3_image','2953'),(191823,6976,'_content_blocks_0_images_3_image','field_6170d8e99800e'),(191824,6976,'content_blocks_0_images_3_header','Good Finish'),(191825,6976,'_content_blocks_0_images_3_header','field_6170d8f49800f'),(191826,6976,'content_blocks_0_images_3_description',''),(191827,6976,'_content_blocks_0_images_3_description','field_6170d90398010'),(191828,6976,'content_blocks_0_images_4_image','2954'),(191829,6976,'_content_blocks_0_images_4_image','field_6170d8e99800e'),(191830,6976,'content_blocks_0_images_4_header','Excellent Finish ± 0.005\"'),(191831,6976,'_content_blocks_0_images_4_header','field_6170d8f49800f'),(191832,6976,'content_blocks_0_images_4_description',''),(191833,6976,'_content_blocks_0_images_4_description','field_6170d90398010'),(191834,6976,'content_blocks_0_images','5'),(191835,6976,'_content_blocks_0_images','field_6170d8df9800d'),(191836,6976,'content_blocks_1_header','Pump Specification'),(191837,6976,'_content_blocks_1_header','field_6170d8ba9800b'),(191838,6976,'content_blocks_1_description','Every waterjet company will be able to supply a chart similar to the following showing the horsepower, maximum pressure and maximum water output for the pumps offered with their systems.'),(191839,6976,'_content_blocks_1_description','field_6170d8cd9800c'),(191840,6976,'content_blocks_1_images_0_image',''),(191841,6976,'_content_blocks_1_images_0_image','field_6170d8e99800e'),(191842,6976,'content_blocks_1_images_0_header',''),(191843,6976,'_content_blocks_1_images_0_header','field_6170d8f49800f'),(191844,6976,'content_blocks_1_images_0_description',''),(191845,6976,'_content_blocks_1_images_0_description','field_6170d90398010'),(191846,6976,'content_blocks_1_images','1'),(191847,6976,'_content_blocks_1_images','field_6170d8df9800d'),(191848,6976,'content_blocks_2_header','Horsepower, pressure and water output'),(191849,6976,'_content_blocks_2_header','field_6170d8ba9800b'),(191850,6976,'content_blocks_2_description','In order to achieve a required edge quality, cutting speed, tolerance and production requirement in a cost-effective manner, understanding the relationship amongst horsepower, pressure and water output is vital. These factors will determine the maximum size orifice you will be able to use, the maximum number of cutting heads you will be able to run, what speeds you will be able to cut at and the maximum thickness you will be able to cut cost effectively.'),(191851,6976,'_content_blocks_2_description','field_6170d8cd9800c'),(191852,6976,'content_blocks_2_images',''),(191853,6976,'_content_blocks_2_images','field_6170d8df9800d'),(191854,6976,'content_blocks_3_header','Horsepower'),(191855,6976,'_content_blocks_3_header','field_6170d8ba9800b'),(191856,6976,'content_blocks_3_description','Waterjet pumps are specified in either horsepower (HP) or kilowatts (kW) to indicate the size of the electric motor that creates the force to pressurize the water. Engineers will size the hydraulic motor depending upon the water pressure and water output they are trying to achieve.\r\n\r\nThe most common pumps seen on the market today are intensifier style pumps. A simplified diagram of the intensifier concept is shown below. The pumps use hydraulics to apply a certain amount of oil pressure on one side of a piston of a certain diameter. On the water side of the pump, the diameter of the piston is much smaller. The difference in the surface area between the hydraulic side and the water side gives a multiplication factor, or intensification, to the pressure from the oil side. Most intensifier pumps have an intensification ratio of 20 times. This design will be explained in more detail in the “How it Works” chapter.\r\n\r\n&nbsp;\r\n\r\n<img class=\"size-full wp-image-2849 aligncenter\" src=\"http://www.wardjet.com/wp-content/uploads/2021/10/Waterjet-University_Nozzle-n-Orifice-Intensifier-Pump-Chart.jpg\" alt=\"Waterjet University_Nozzle n Orifice Intensifier Pump Chart\" width=\"645\" height=\"284\" />'),(191857,6976,'_content_blocks_3_description','field_6170d8cd9800c'),(191858,6976,'content_blocks_3_images_0_image','2849'),(191859,6976,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(191860,6976,'content_blocks_3_images_0_header',''),(191861,6976,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(191862,6976,'content_blocks_3_images_0_description',''),(191863,6976,'_content_blocks_3_images_0_description','field_6170d90398010'),(191864,6976,'content_blocks_3_images','1'),(191865,6976,'_content_blocks_3_images','field_6170d8df9800d'),(191866,6976,'content_blocks_4_header',''),(191867,6976,'_content_blocks_4_header','field_6170d8ba9800b'),(191868,6976,'content_blocks_4_description','Another style pump sometimes used on waterjets is the direct drive pump. This pump uses an electric motor to turn a crankshaft that moves three or more pistons that create the water pressure, very similar to a car engine. Faster revolutions of the motor create higher pressure and more water volume. The basic concept for the direct drive is shown below.'),(191869,6976,'_content_blocks_4_description','field_6170d8cd9800c'),(191870,6976,'content_blocks_4_images_0_image','2850'),(191871,6976,'_content_blocks_4_images_0_image','field_6170d8e99800e'),(191872,6976,'content_blocks_4_images_0_header',''),(191873,6976,'_content_blocks_4_images_0_header','field_6170d8f49800f'),(191874,6976,'content_blocks_4_images_0_description',''),(191875,6976,'_content_blocks_4_images_0_description','field_6170d90398010'),(191876,6976,'content_blocks_4_images_1_image','6975'),(191877,6976,'_content_blocks_4_images_1_image','field_6170d8e99800e'),(191878,6976,'content_blocks_4_images_1_header',''),(191879,6976,'_content_blocks_4_images_1_header','field_6170d8f49800f'),(191880,6976,'content_blocks_4_images_1_description',''),(191881,6976,'_content_blocks_4_images_1_description','field_6170d90398010'),(191882,6976,'content_blocks_4_images','2'),(191883,6976,'_content_blocks_4_images','field_6170d8df9800d'),(191884,6976,'content_blocks_5_header',''),(191885,6976,'_content_blocks_5_header','field_6170d8ba9800b'),(191886,6976,'content_blocks_5_description','The horsepower between an intensifier style pump and a direct drive pump cannot be directly compared. Each style pump has benefits and drawbacks that must be evaluated based upon each user’s application.\r\n\r\nThe question frequently comes up as to which is better, a direct drive or an intensifier pump. Of course depending upon which manufacturer with which you are talking, you will get different answers. The best way to answer this is to ask the following questions and do your own research:\r\n<ul>\r\n 	<li>What percentage of pumps in use today are intensifier as opposed to direct drive?</li>\r\n 	<li>What percentage of new machines being sold today have intensifier pumps versus direct drive?</li>\r\n 	<li>How many businesses have been created to swap out a direct drive pump with a retrofit kit to change over to an intensifier – basically dispose of the direct drive?</li>\r\n 	<li>How many businesses have been created to swap out an intensifier pump for a direct drive – in other words dispose of an intensifier pump?</li>\r\n 	<li>What are the maintenance costs associated with each style pump for the first 1500 hours, including replacement of consumable and spare parts?</li>\r\n 	<li>How much downtime is involved to replace consumable and spare parts on each style pump?</li>\r\n</ul>'),(191887,6976,'_content_blocks_5_description','field_6170d8cd9800c'),(191888,6976,'content_blocks_5_images',''),(191889,6976,'_content_blocks_5_images','field_6170d8df9800d'),(191890,6976,'content_blocks','19'),(191891,6976,'_content_blocks','field_6170d8ac9800a'),(191892,6976,'menu','37'),(191893,6976,'_menu','field_6170d9e059837'),(191894,6976,'display_left_column','1'),(191895,6976,'_display_left_column','field_613563c4d424b'),(191896,6976,'contact_left_heading',''),(191897,6976,'_contact_left_heading','field_60c249d645c99'),(191898,6976,'contact_left_copy',''),(191899,6976,'_contact_left_copy','field_60c24a0845c9c'),(191900,6976,'display_right_column','1'),(191901,6976,'_display_right_column','field_613563f4d424c'),(191902,6976,'contact_right_heading',''),(191903,6976,'_contact_right_heading','field_60c249e945c9a'),(191904,6976,'contact_right_copy',''),(191905,6976,'_contact_right_copy','field_60c249f845c9b'),(191906,6976,'contact_right_cta',''),(191907,6976,'_contact_right_cta','field_60c24a1945c9d'),(191908,6976,'content_blocks_6_header','Pressure'),(191909,6976,'_content_blocks_6_header','field_6170d8ba9800b'),(191910,6976,'content_blocks_6_description','The pressure of the pump, measured in PSI, will determine cutting speeds for a given orifice size and number of heads. All other things being equal, there is an almost direct correlation between pressure and cutting speed; higher pressure results in higher cutting speeds. From a practical standpoint, increasing pressure also results in higher pump consumable costs, so that must be weighed against the faster cutting speeds.\r\n\r\nThe following graph shows the cutting speeds for ½” (12 mm) stainless steel for a Quality 2 edge finish. The two lines represent two common combinations of orifices and abrasive nozzles. In each case, doubling the pressure from 30,000 psi (2068 bar) to 60,000 psi (4137 bar) results in an increase in linear cutting speed of approximately 2.9 times.\r\n\r\n<b>IMPORTANT:</b> Keep in mind that pump horsepower is not always a direct indication of maximum pressure for the pump. A 200 HP pump may not necessarily have higher pressure than a 100 HP or 50 HP pump.'),(191911,6976,'_content_blocks_6_description','field_6170d8cd9800c'),(191912,6976,'content_blocks_6_images','1'),(191913,6976,'_content_blocks_6_images','field_6170d8df9800d'),(191914,6976,'content_blocks_6_images_0_image','2958'),(191915,6976,'_content_blocks_6_images_0_image','field_6170d8e99800e'),(191916,6976,'content_blocks_6_images_0_header',''),(191917,6976,'_content_blocks_6_images_0_header','field_6170d8f49800f'),(191918,6976,'content_blocks_6_images_0_description',''),(191919,6976,'_content_blocks_6_images_0_description','field_6170d90398010'),(191920,6976,'content_blocks_7_header','Water Output'),(191921,6976,'_content_blocks_7_header','field_6170d8ba9800b'),(191922,6976,'content_blocks_7_description','Water output, or flow rate, is a function of horsepower and pressure. A 50 HP intensifier pump running at 60,000 psi will generally have a maximum output of 1 gallon per minute (gpm). A 100 HP pump running at 60,000 psi will typically put out 2 gpm. This information will help you determine the maximum number of cutting heads that you can use with a pump. Different pump manufacturers will produce slightly different volumes. They may also specify a Maximum Output Pressure and an Operating Output Pressure with different associated water outputs. It is important to verify that the water output specified is what you can expect on a regular production basis (i.e. flow rate based off of Operating Output Pressure).'),(191923,6976,'_content_blocks_7_description','field_6170d8cd9800c'),(191924,6976,'content_blocks_7_images',''),(191925,6976,'_content_blocks_7_images','field_6170d8df9800d'),(191926,6976,'content_blocks_8_header','Orifice selection – The scientific way'),(191927,6976,'_content_blocks_8_header','field_6170d8ba9800b'),(191928,6976,'content_blocks_8_description','The Maximum Continuous Output Pressure and Maximum Output Flow from the “Pump Specifications” in Figure 1 are important in order to understand how many cutting heads you will be able to run with a pump. These numbers can be used in conjunction with the following “Flow Rate Through an Orifice” in Figure 2 to determine the number of cutting heads you can use.\r\n\r\n<b>Example 1</b>: 50 HP Pump, 1 Cutting Head, 60,000 PSI, 1.1 GPM water output\r\n<ol class=\"steps\">\r\n 	<li>If you were looking at the 50 HP pump, from the “Pump Specification” chart you would know that your pump puts out 1.1 gpm at 60,000 psi.</li>\r\n 	<li>You would look down under the “60” column (corresponding to the 60,000 psi pump) in the “Flow Rate” chart until you found a number equal to or less than 1.1. In this case, you would end up at the cell with 1.00.</li>\r\n 	<li>You would then follow that row across to the left to see the maximum size orifice you could use for single-head cutting. In this case, the cell shows that a 0.014” would be the maximum recommended orifice for one head at 60,000 psi.</li>\r\n 	<li>If you were in a tight spot where you only had a 0.015” orifice you might be able to use it by running the pump at 55,000 psi.</li>\r\n</ol>\r\nYou would be at the 1.1 gpm limitation of the pump. If there were any water leaks in your system between the pump and the cutting head, you would likely have a pump “over stroke” situation where the pump would try to cycle too fast attempting to create the required pressure. With modern pumps, there is no harm done if this happens. The pump is simply shut down to protect itself from damage and an error message is displayed for the operator.'),(191929,6976,'_content_blocks_8_description','field_6170d8cd9800c'),(191930,6976,'content_blocks_8_images','1'),(191931,6976,'_content_blocks_8_images','field_6170d8df9800d'),(191932,6976,'content_blocks_8_images_0_image',''),(191933,6976,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(191934,6976,'content_blocks_8_images_0_header','chart needed here'),(191935,6976,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(191936,6976,'content_blocks_8_images_0_description',''),(191937,6976,'_content_blocks_8_images_0_description','field_6170d90398010'),(191938,6976,'content_blocks_9_header','Running Two Cutting Heads'),(191939,6976,'_content_blocks_9_header','field_6170d8ba9800b'),(191940,6976,'content_blocks_9_description','<b>Example 2</b> 50 HP Pump, 2 Cutting Heads, 60,000 PSI, 1.1 GPM water output\r\n\r\nIf you wanted to run 2 cutting heads, then you would take the 1.1 gpm number, divide it by 2 for a maximum of 0.55 gpm per head. Look for the cell under 60 kpsi that has a number smaller than or equal to 0.55. In this case, under the “60” column you would end up in the 0.51 cell, meaning that one 0.010” orifice would put out 0.51 gpm. The maximum number of heads that you could run with the pump at 60 kpsi would be two (1.1 ÷ 2 = 0.55. 0.55 &gt; 0.51 = OK).'),(191941,6976,'_content_blocks_9_description','field_6170d8cd9800c'),(191942,6976,'content_blocks_9_images',''),(191943,6976,'_content_blocks_9_images','field_6170d8df9800d'),(191944,6976,'content_blocks_10_header','Orifice selection – the easy way'),(191945,6976,'_content_blocks_10_header','field_6170d8ba9800b'),(191946,6976,'content_blocks_10_description','Since the pump design engineers have done most of the hard math already, most users need only refer to an “Orifice Selection Chart” similar to the following, which is usually supplied by the pump manufacturer. Here you would quickly see that for the 50 HP pump, you could use either one 0.014” orifice or two 0.010” orifices.'),(191947,6976,'_content_blocks_10_description','field_6170d8cd9800c'),(191948,6976,'content_blocks_10_images_0_image',''),(191949,6976,'_content_blocks_10_images_0_image','field_6170d8e99800e'),(191950,6976,'content_blocks_10_images_0_header','insert table'),(191951,6976,'_content_blocks_10_images_0_header','field_6170d8f49800f'),(191952,6976,'content_blocks_10_images_0_description',''),(191953,6976,'_content_blocks_10_images_0_description','field_6170d90398010'),(191954,6976,'content_blocks_10_images','1'),(191955,6976,'_content_blocks_10_images','field_6170d8df9800d'),(191956,6976,'content_blocks_11_header','General pump selection guidelines'),(191957,6976,'_content_blocks_11_header','field_6170d8ba9800b'),(191958,6976,'content_blocks_11_description','The next step in determining which pump is appropriate for your application is to determine the types of material you will be cutting and how many cutting heads you want to be able to run at one time.\r\n\r\nIf you are cutting parts out of foam, wood, cardboard or other soft materials, then you would be dealing with a pure water application. For pure water applications, a 30 HP pump is usually sufficient. As you can see from the previous Orifice Selection chart, up to three cutting heads could be used with 0.006” orifices.\r\n\r\nIf more cutting heads were needed, then a 50 HP pump could handle up to five cutting heads with 0.006” orifices. For abrasive applications, the 50 HP is the general starting point. With this pump, you can run one head with a 0.014” orifice or two heads with 0.010” orifices. The 0.010” orifice will perform exceptionally well with respect to speed and cut quality on thinner material (1/2” and under).\r\n\r\nThe following graph shows cutting speeds for single head versus dual head cutting in ½” stainless steel. As thickness get beyond 2” (50 mm), the absolute difference in cutting speeds between the nozzle combinations starts to decrease more dramatically.\r\n\r\nCutting with two heads with 0.010” orifices effectively doubles the cutting speed (2 x 5.5 ipm) versus cutting with one head with a 0.010” orifice. Compared to cutting with one head with the 0.014” orifice, cutting with two heads will increase output by about 20 percent. To put this concept into real world terms, it would be like if you started cutting on a job on Monday morning with two cutting heads, then you could get it to your customer by Thursday afternoon. If you cut the job with one head, your customer wouldn’t get the part until Friday afternoon.\r\n\r\nFor someone looking to cut thicker materials on a consistent basis, then we would suggest allocating 50 HP per cutting head. If you selected a 100 HP pump, you could run two heads with 0.014”.\r\n\r\nIf you are cutting very small parts in high volumes, you might want a very large cutting table where you could run four cutting heads and quadruple your production over a single-headed system. In that case you would likely choose the 150 HP pump that can run four heads with 0.013” orifices.'),(191959,6976,'_content_blocks_11_description','field_6170d8cd9800c'),(191960,6976,'content_blocks_11_images_0_image','2960'),(191961,6976,'_content_blocks_11_images_0_image','field_6170d8e99800e'),(191962,6976,'content_blocks_11_images_0_header',''),(191963,6976,'_content_blocks_11_images_0_header','field_6170d8f49800f'),(191964,6976,'content_blocks_11_images_0_description',''),(191965,6976,'_content_blocks_11_images_0_description','field_6170d90398010'),(191966,6976,'content_blocks_11_images','1'),(191967,6976,'_content_blocks_11_images','field_6170d8df9800d'),(191968,6976,'content_blocks_12_header','Abrasive nozzle selection'),(191969,6976,'_content_blocks_12_header','field_6170d8ba9800b'),(191970,6976,'content_blocks_12_description','As a general rule, the diameter of the orifice for the abrasive nozzle should be approximately three times the water nozzle orifice.\r\n\r\nSome people would suggest using a smaller ratio, about 2.5 times. Using a smaller ratio does produce faster cutting speeds. The trade-off is increased nozzle wear and costs. Part tolerance will suffer because of the increased speed of nozzle wear.\r\n\r\nFollowing is a quick reference guide for the most common orifices for abrasive waterjet cutting. Typical abrasive amounts and water flow are also shown for easy reference.'),(191971,6976,'_content_blocks_12_description','field_6170d8cd9800c'),(191972,6976,'content_blocks_12_images_0_image',''),(191973,6976,'_content_blocks_12_images_0_image','field_6170d8e99800e'),(191974,6976,'content_blocks_12_images_0_header','insert chart'),(191975,6976,'_content_blocks_12_images_0_header','field_6170d8f49800f'),(191976,6976,'content_blocks_12_images_0_description',''),(191977,6976,'_content_blocks_12_images_0_description','field_6170d90398010'),(191978,6976,'content_blocks_12_images','1'),(191979,6976,'_content_blocks_12_images','field_6170d8df9800d'),(191980,6976,'content_blocks_13_header','Abrasive amount and cutting speeds'),(191981,6976,'_content_blocks_13_header','field_6170d8ba9800b'),(191982,6976,'content_blocks_13_description','As abrasive is added to the waterjet stream, the abrasive particles are accelerated to near the speed of the waterjet, approximately 2200 miles per hour (almost three times the speed of sound). This speed imparts momentum to the abrasive particles so that they can erode the material. Adding more abrasive gives more energy to the process and erosion occurs faster. Eventually a saturation point occurs where adding more abrasive robs speed and power from the waterjet stream and cutting speeds will start to decrease. Each waterjet manufacturer goes through extensive testing with various orifice and nozzle combinations to find the optimum abrasive amount, balancing cost and cutting speed.\r\n\r\nThe following graph shows what happens to cutting speed for ½” stainless steel as abrasive is added. Speeds are shown for the two most common orifice/abrasive nozzle combinations, 0.010” orifice with a 0.030” abrasive nozzle (orange line) and 0.014” orifice with a 0.040” abrasive nozzle (blue line).\r\n\r\nStarting with an abrasive flow of zero pounds per minute, there would be absolutely no penetration of the material except for maybe a very light etching of the top surface of the material. At this point cutting speed is zero. Cutting speed increases as more and more abrasive is added. For the larger nozzle combination, speed increases until around 1.5 pounds per minute. At this point, cutting speed starts to decrease as too much kinetic energy is removed from the waterjet stream by the abrasive. A similar thing happens with the smaller orifice/nozzle combination, but at slower speeds and lower abrasive amounts.\r\n\r\nThe optimum cost point may be slightly below what looks to be the apex of the speed curve. The “Law of Diminishing Returns” becomes evident. As the maximum speed is approached, each additional unit of abrasive that is added results in an ever smaller increase in speed. In the case of the orange line, increasing the abrasive from 0.7 pounds per minute to 1.0 pounds per minute yields an increase in speed of only 0.2 inches per minute. This 3.6% increase in speed results in a 4.7% increase in cost per inch.'),(191983,6976,'_content_blocks_13_description','field_6170d8cd9800c'),(191984,6976,'content_blocks_13_images_0_image','2830'),(191985,6976,'_content_blocks_13_images_0_image','field_6170d8e99800e'),(191986,6976,'content_blocks_13_images_0_header',''),(191987,6976,'_content_blocks_13_images_0_header','field_6170d8f49800f'),(191988,6976,'content_blocks_13_images_0_description','In Chapter 1, “Cutting Characteristics,” under the section “Creation of the abrasive waterjet stream”, we discussed how the abrasive waterjet stream is created. The cross-section of the cutting head is shown again here.'),(191989,6976,'_content_blocks_13_images_0_description','field_6170d90398010'),(191990,6976,'content_blocks_13_images_1_image','2961'),(191991,6976,'_content_blocks_13_images_1_image','field_6170d8e99800e'),(191992,6976,'content_blocks_13_images_1_header',''),(191993,6976,'_content_blocks_13_images_1_header','field_6170d8f49800f'),(191994,6976,'content_blocks_13_images_1_description',''),(191995,6976,'_content_blocks_13_images_1_description','field_6170d90398010'),(191996,6976,'content_blocks_13_images','2'),(191997,6976,'_content_blocks_13_images','field_6170d8df9800d'),(191998,6976,'content_blocks_14_header','Speed and efficiency of nozzle combinations'),(191999,6976,'_content_blocks_14_header','field_6170d8ba9800b'),(192000,6976,'content_blocks_14_description','We can see in the following graph that larger orifice/abrasive nozzle combinations will cut faster than smaller combinations. With the larger nozzle combination, virtually all of the pump’s power is used, so it will cut faster. The smaller orifice/nozzle cuts slower because less total power from the pump is used.'),(192001,6976,'_content_blocks_14_description','field_6170d8cd9800c'),(192002,6976,'content_blocks_14_images_0_image','2961'),(192003,6976,'_content_blocks_14_images_0_image','field_6170d8e99800e'),(192004,6976,'content_blocks_14_images_0_header',''),(192005,6976,'_content_blocks_14_images_0_header','field_6170d8f49800f'),(192006,6976,'content_blocks_14_images_0_description','Smaller orifice/nozzle combinations are more efficient though in their use of water and abrasive. The available power of the waterjet is concentrated into a smaller area, so more power is directed to the cut.'),(192007,6976,'_content_blocks_14_images_0_description','field_6170d90398010'),(192008,6976,'content_blocks_14_images_1_image','2962'),(192009,6976,'_content_blocks_14_images_1_image','field_6170d8e99800e'),(192010,6976,'content_blocks_14_images_1_header',''),(192011,6976,'_content_blocks_14_images_1_header','field_6170d8f49800f'),(192012,6976,'content_blocks_14_images_1_description','In the picture above, the diameter of the larger waterjet stream on the right is 33% wider and the area of this diameter is 78% greater. This makes the energy density lower than the smaller orifice/nozzle combination. The result is that, as shown earlier and repeated in the graph below, cutting with two 0.010”/0.030” heads is more cost-effective and productive than cutting with one 0.014”/0.040” head in thinner materials (approximately ½” and thinner).'),(192013,6976,'_content_blocks_14_images_1_description','field_6170d90398010'),(192014,6976,'content_blocks_14_images_2_image','2963'),(192015,6976,'_content_blocks_14_images_2_image','field_6170d8e99800e'),(192016,6976,'content_blocks_14_images_2_header',''),(192017,6976,'_content_blocks_14_images_2_header','field_6170d8f49800f'),(192018,6976,'content_blocks_14_images_2_description',''),(192019,6976,'_content_blocks_14_images_2_description','field_6170d90398010'),(192020,6976,'content_blocks_14_images','3'),(192021,6976,'_content_blocks_14_images','field_6170d8df9800d'),(192022,6976,'content_blocks_15_header','Nozzle wear'),(192023,6976,'_content_blocks_15_header','field_6170d8ba9800b'),(192024,6976,'content_blocks_15_description','As the abrasive nozzle wears, the diameter of the abrasive waterjet stream increases. The diameter increases by approximately 0.0001” per hour of cutting. Power per square inch is reduced. Therefore, the feed rate must be reduced in order to maintain the same edge finish, or the quality of the edge will deteriorate.'),(192025,6976,'_content_blocks_15_description','field_6170d8cd9800c'),(192026,6976,'content_blocks_15_images',''),(192027,6976,'_content_blocks_15_images','field_6170d8df9800d'),(192028,6976,'content_blocks_16_header','Cutting speed calculators'),(192029,6976,'_content_blocks_16_header','field_6170d8ba9800b'),(192030,6976,'content_blocks_16_description','Various waterjet feed rate calculators are available online. With these calculators, you can play around with the various parameters to see how cutting speed and cost per inch are affected. Below is an example of one such calculator.\r\n\r\nWith all of these calculators, it is more important to focus on cost per inch (or foot, or meter), rather than cost per hour. Focusing on cost per foot takes into account the diminishing returns discussed in the previous section.\r\n\r\nAnother thing to keep in mind is that these calculators are only showing straight line cutting speeds. Depending upon part geometry, piercing times, machine design and more, actual part cutting times can vary significantly from just taking the total linear inches of cutting in a part and dividing that number by the inches per minute shown in a calculator. The calculators are useful though in at least getting an idea of speeds and costs.'),(192031,6976,'_content_blocks_16_description','field_6170d8cd9800c'),(192032,6976,'content_blocks_16_images_0_image','2965'),(192033,6976,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(192034,6976,'content_blocks_16_images_0_header',''),(192035,6976,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(192036,6976,'content_blocks_16_images_0_description',''),(192037,6976,'_content_blocks_16_images_0_description','field_6170d90398010'),(192038,6976,'content_blocks_16_images','1'),(192039,6976,'_content_blocks_16_images','field_6170d8df9800d'),(192040,6976,'content_blocks_17_header','Machinability Index'),(192041,6976,'_content_blocks_17_header','field_6170d8ba9800b'),(192042,6976,'content_blocks_17_description','The Machinability Index shown in most waterjet feed rate calculators defines the relative cutting rates of different materials. Materials with higher numbers cut proportionately faster than lower numbers. Mild steel has a baseline value of one. Stainless steel at 0.9 would indicate that it cuts about 10% slower than mild steel to achieve similar edge quality and tolerance results.\r\n\r\nIf you know the machinability indexes of two materials, you can estimate fairly easily a good cutting speed of one material from the other. We know that the Machinability Index of stainless steel is 0.9 and below we see that Aluminum’s Machinability Index is 2.9. You know that ½” stainless cuts at 5.5 ipm for the edge quality you want. You want to know the speed for ½” Aluminum. Divide the machinability of Aluminum by the machinability of stainless. 2.9 ÷ 0.9 = 3.2. Multiply the cutting speed for Stainless by 3.2 for the cutting speed in the same thickness of Aluminum. 5.5 ipm x 3.2 = 17.6 ipm. Therefore, 17.6 ipm would be a good place to start for ½” Aluminum.'),(192043,6976,'_content_blocks_17_description','field_6170d8cd9800c'),(192044,6976,'content_blocks_17_images_0_image','2966'),(192045,6976,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(192046,6976,'content_blocks_17_images_0_header',''),(192047,6976,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(192048,6976,'content_blocks_17_images_0_description',''),(192049,6976,'_content_blocks_17_images_0_description','field_6170d90398010'),(192050,6976,'content_blocks_17_images_1_image','2967'),(192051,6976,'_content_blocks_17_images_1_image','field_6170d8e99800e'),(192052,6976,'content_blocks_17_images_1_header',''),(192053,6976,'_content_blocks_17_images_1_header','field_6170d8f49800f'),(192054,6976,'content_blocks_17_images_1_description',''),(192055,6976,'_content_blocks_17_images_1_description','field_6170d90398010'),(192056,6976,'content_blocks_17_images','2'),(192057,6976,'_content_blocks_17_images','field_6170d8df9800d'),(192058,6976,'content_blocks_18_header','Summary'),(192059,6976,'_content_blocks_18_header','field_6170d8ba9800b'),(192060,6976,'content_blocks_18_description','In this chapter we looked at the three critical specifications of a high pressure pump: horsepower, pressure and water output. We reviewed how to figure out what size orifice to use based upon these pump specifications and how many cutting heads are being used. We covered the productivity increases and cost savings of using two smaller orifices versus one large orifice. Additionally, abrasive nozzle diameter selection was discussed in terms of the ratio to the orifice being used. Finally, we looked at waterjet feed rate calculators and how Machinability Indices can be used to extrapolate the cutting speed of one material from a different material.'),(192061,6976,'_content_blocks_18_description','field_6170d8cd9800c'),(192062,6976,'content_blocks_18_images',''),(192063,6976,'_content_blocks_18_images','field_6170d8df9800d'),(192067,2850,'_wp_attachment_image_alt','Waterjet University_Nozzle n Orifice Direct Drive Pump Chart'),(192068,2961,'_wp_attachment_image_alt','Waterjet University_Nozzle n Orifice Abrasive Amount and Cutting Speed Chart'),(192069,6977,'_wp_attached_file','2022/03/nozzle-and-orifice-abrasive-amount-chart-2.jpg'),(192070,6977,'_wp_attachment_metadata','a:5:{s:5:\"width\";i:600;s:6:\"height\";i:344;s:4:\"file\";s:54:\"2022/03/nozzle-and-orifice-abrasive-amount-chart-2.jpg\";s:5:\"sizes\";a:2:{s:6:\"medium\";a:4:{s:4:\"file\";s:54:\"nozzle-and-orifice-abrasive-amount-chart-2-300x172.jpg\";s:5:\"width\";i:300;s:6:\"height\";i:172;s:9:\"mime-type\";s:10:\"image/jpeg\";}s:9:\"thumbnail\";a:4:{s:4:\"file\";s:54:\"nozzle-and-orifice-abrasive-amount-chart-2-150x150.jpg\";s:5:\"width\";i:150;s:6:\"height\";i:150;s:9:\"mime-type\";s:10:\"image/jpeg\";}}s:10:\"image_meta\";a:12:{s:8:\"aperture\";s:1:\"0\";s:6:\"credit\";s:0:\"\";s:6:\"camera\";s:0:\"\";s:7:\"caption\";s:0:\"\";s:17:\"created_timestamp\";s:1:\"0\";s:9:\"copyright\";s:0:\"\";s:12:\"focal_length\";s:1:\"0\";s:3:\"iso\";s:1:\"0\";s:13:\"shutter_speed\";s:1:\"0\";s:5:\"title\";s:0:\"\";s:11:\"orientation\";s:1:\"0\";s:8:\"keywords\";a:0:{}}}'),(192071,6977,'_wp_attachment_image_alt','nozzle and orifice - abrasive-amount-chart-2'),(192072,2962,'_wp_attachment_image_alt','Waterjet University_Nozzle n Orifice Nozzle Combination Chart 2'),(192073,2848,'rank_math_description','Read about n relationships between speed and edge quality, pump size, water nozzle and abrasive nozzle selection, maximum number of cutting heads and more.'),(192074,2848,'rank_math_focus_keyword','nozzle and orifice'),(192075,6977,'_wpml_media_usage','a:1:{s:5:\"posts\";a:1:{i:0;i:2848;}}'),(192076,6978,'hero_gallery',''),(192077,6978,'_hero_gallery','field_60c23d554e4a3'),(192078,6978,'hero_banner','6956'),(192079,6978,'_hero_banner','field_6170dbe179470'),(192080,6978,'page_title','Nozzle and Orifice'),(192081,6978,'_page_title','field_6170d88998008'),(192082,6978,'page_description','This section will focus on relationships between speed and edge quality, pump size, water nozzle and abrasive nozzle selection, maximum number of cutting heads and how some of these parameters can change over time.'),(192083,6978,'_page_description','field_6170d89398009'),(192084,6978,'content_blocks_0_header','Desired edge quality'),(192085,6978,'_content_blocks_0_header','field_6170d8ba9800b'),(192086,6978,'content_blocks_0_description','Edge quality is defined with the numbers 1 through 5. Lower numbers indicate rougher edge finish; higher numbers are smoother. For thin materials, the difference in cutting speed for Quality 1 could be as much as 3 times faster than the speed for Quality 5. For thicker materials, Quality 1 could be 6 times faster than Quality 5. For example, 4” thick Aluminum Q5 would be 0.72 ipm (18 mm/min) and Q1 would be 4.2 ipm (107 mm/min), 5.8 times faster.'),(192087,6978,'_content_blocks_0_description','field_6170d8cd9800c'),(192088,6978,'content_blocks_0_images_0_image','2950'),(192089,6978,'_content_blocks_0_images_0_image','field_6170d8e99800e'),(192090,6978,'content_blocks_0_images_0_header','Seperation Cut'),(192091,6978,'_content_blocks_0_images_0_header','field_6170d8f49800f'),(192092,6978,'content_blocks_0_images_0_description',''),(192093,6978,'_content_blocks_0_images_0_description','field_6170d90398010'),(192094,6978,'content_blocks_0_images_1_image','2951'),(192095,6978,'_content_blocks_0_images_1_image','field_6170d8e99800e'),(192096,6978,'content_blocks_0_images_1_header','Through Cut'),(192097,6978,'_content_blocks_0_images_1_header','field_6170d8f49800f'),(192098,6978,'content_blocks_0_images_1_description',''),(192099,6978,'_content_blocks_0_images_1_description','field_6170d90398010'),(192100,6978,'content_blocks_0_images_2_image','2952'),(192101,6978,'_content_blocks_0_images_2_image','field_6170d8e99800e'),(192102,6978,'content_blocks_0_images_2_header','Clean Cut ± 0.010\"'),(192103,6978,'_content_blocks_0_images_2_header','field_6170d8f49800f'),(192104,6978,'content_blocks_0_images_2_description',''),(192105,6978,'_content_blocks_0_images_2_description','field_6170d90398010'),(192106,6978,'content_blocks_0_images_3_image','2953'),(192107,6978,'_content_blocks_0_images_3_image','field_6170d8e99800e'),(192108,6978,'content_blocks_0_images_3_header','Good Finish'),(192109,6978,'_content_blocks_0_images_3_header','field_6170d8f49800f'),(192110,6978,'content_blocks_0_images_3_description',''),(192111,6978,'_content_blocks_0_images_3_description','field_6170d90398010'),(192112,6978,'content_blocks_0_images_4_image','2954'),(192113,6978,'_content_blocks_0_images_4_image','field_6170d8e99800e'),(192114,6978,'content_blocks_0_images_4_header','Excellent Finish ± 0.005\"'),(192115,6978,'_content_blocks_0_images_4_header','field_6170d8f49800f'),(192116,6978,'content_blocks_0_images_4_description',''),(192117,6978,'_content_blocks_0_images_4_description','field_6170d90398010'),(192118,6978,'content_blocks_0_images','5'),(192119,6978,'_content_blocks_0_images','field_6170d8df9800d'),(192120,6978,'content_blocks_1_header','Pump Specification'),(192121,6978,'_content_blocks_1_header','field_6170d8ba9800b'),(192122,6978,'content_blocks_1_description','Every waterjet company will be able to supply a chart similar to the following showing the horsepower, maximum pressure and maximum water output for the pumps offered with their systems.'),(192123,6978,'_content_blocks_1_description','field_6170d8cd9800c'),(192124,6978,'content_blocks_1_images_0_image',''),(192125,6978,'_content_blocks_1_images_0_image','field_6170d8e99800e'),(192126,6978,'content_blocks_1_images_0_header',''),(192127,6978,'_content_blocks_1_images_0_header','field_6170d8f49800f'),(192128,6978,'content_blocks_1_images_0_description',''),(192129,6978,'_content_blocks_1_images_0_description','field_6170d90398010'),(192130,6978,'content_blocks_1_images','1'),(192131,6978,'_content_blocks_1_images','field_6170d8df9800d'),(192132,6978,'content_blocks_2_header','Horsepower, pressure and water output'),(192133,6978,'_content_blocks_2_header','field_6170d8ba9800b'),(192134,6978,'content_blocks_2_description','In order to achieve a required edge quality, cutting speed, tolerance and production requirement in a cost-effective manner, understanding the relationship amongst horsepower, pressure and water output is vital. These factors will determine the maximum size orifice you will be able to use, the maximum number of cutting heads you will be able to run, what speeds you will be able to cut at and the maximum thickness you will be able to cut cost effectively.'),(192135,6978,'_content_blocks_2_description','field_6170d8cd9800c'),(192136,6978,'content_blocks_2_images',''),(192137,6978,'_content_blocks_2_images','field_6170d8df9800d'),(192138,6978,'content_blocks_3_header','Horsepower'),(192139,6978,'_content_blocks_3_header','field_6170d8ba9800b'),(192140,6978,'content_blocks_3_description','Waterjet pumps are specified in either horsepower (HP) or kilowatts (kW) to indicate the size of the electric motor that creates the force to pressurize the water. Engineers will size the hydraulic motor depending upon the water pressure and water output they are trying to achieve.\r\n\r\nThe most common pumps seen on the market today are intensifier style pumps. A simplified diagram of the intensifier concept is shown below. The pumps use hydraulics to apply a certain amount of oil pressure on one side of a piston of a certain diameter. On the water side of the pump, the diameter of the piston is much smaller. The difference in the surface area between the hydraulic side and the water side gives a multiplication factor, or intensification, to the pressure from the oil side. Most intensifier pumps have an intensification ratio of 20 times. This design will be explained in more detail in the “How it Works” chapter.\r\n\r\n&nbsp;\r\n\r\n<img class=\"size-full wp-image-2849 aligncenter\" src=\"http://www.wardjet.com/wp-content/uploads/2021/10/Waterjet-University_Nozzle-n-Orifice-Intensifier-Pump-Chart.jpg\" alt=\"Waterjet University_Nozzle n Orifice Intensifier Pump Chart\" width=\"645\" height=\"284\" />'),(192141,6978,'_content_blocks_3_description','field_6170d8cd9800c'),(192142,6978,'content_blocks_3_images_0_image','2849'),(192143,6978,'_content_blocks_3_images_0_image','field_6170d8e99800e'),(192144,6978,'content_blocks_3_images_0_header',''),(192145,6978,'_content_blocks_3_images_0_header','field_6170d8f49800f'),(192146,6978,'content_blocks_3_images_0_description',''),(192147,6978,'_content_blocks_3_images_0_description','field_6170d90398010'),(192148,6978,'content_blocks_3_images','1'),(192149,6978,'_content_blocks_3_images','field_6170d8df9800d'),(192150,6978,'content_blocks_4_header',''),(192151,6978,'_content_blocks_4_header','field_6170d8ba9800b'),(192152,6978,'content_blocks_4_description','Another style pump sometimes used on waterjets is the direct drive pump. This pump uses an electric motor to turn a crankshaft that moves three or more pistons that create the water pressure, very similar to a car engine. Faster revolutions of the motor create higher pressure and more water volume. The basic concept for the direct drive is shown below.\r\n\r\n&nbsp;\r\n\r\n<img class=\"alignnone size-full wp-image-2850\" src=\"http://www.wardjet.com/wp-content/uploads/2021/10/Waterjet-University_Nozzle-n-Orifice-Direct-Drive-Pump-Chart.jpg\" alt=\"Waterjet University_Nozzle n Orifice Direct Drive Pump Chart\" width=\"450\" />\r\n\r\n<img class=\"alignnone size-medium wp-image-6975\" src=\"http://www.wardjet.com/wp-content/uploads/2022/03/nozzle-and-orifice-direct-drive-300x211.jpg\" alt=\"nozzle and orifice direct drive\" width=\"450\"  />'),(192153,6978,'_content_blocks_4_description','field_6170d8cd9800c'),(192154,6978,'content_blocks_4_images',''),(192155,6978,'_content_blocks_4_images','field_6170d8df9800d'),(192156,6978,'content_blocks_5_header',''),(192157,6978,'_content_blocks_5_header','field_6170d8ba9800b'),(192158,6978,'content_blocks_5_description','The horsepower between an intensifier style pump and a direct drive pump cannot be directly compared. Each style pump has benefits and drawbacks that must be evaluated based upon each user’s application.\r\n\r\nThe question frequently comes up as to which is better, a direct drive or an intensifier pump. Of course depending upon which manufacturer with which you are talking, you will get different answers. The best way to answer this is to ask the following questions and do your own research:\r\n<ul>\r\n 	<li>What percentage of pumps in use today are intensifier as opposed to direct drive?</li>\r\n 	<li>What percentage of new machines being sold today have intensifier pumps versus direct drive?</li>\r\n 	<li>How many businesses have been created to swap out a direct drive pump with a retrofit kit to change over to an intensifier – basically dispose of the direct drive?</li>\r\n 	<li>How many businesses have been created to swap out an intensifier pump for a direct drive – in other words dispose of an intensifier pump?</li>\r\n 	<li>What are the maintenance costs associated with each style pump for the first 1500 hours, including replacement of consumable and spare parts?</li>\r\n 	<li>How much downtime is involved to replace consumable and spare parts on each style pump?</li>\r\n</ul>'),(192159,6978,'_content_blocks_5_description','field_6170d8cd9800c'),(192160,6978,'content_blocks_5_images',''),(192161,6978,'_content_blocks_5_images','field_6170d8df9800d'),(192162,6978,'content_blocks','19'),(192163,6978,'_content_blocks','field_6170d8ac9800a'),(192164,6978,'menu','37'),(192165,6978,'_menu','field_6170d9e059837'),(192166,6978,'display_left_column','1'),(192167,6978,'_display_left_column','field_613563c4d424b'),(192168,6978,'contact_left_heading',''),(192169,6978,'_contact_left_heading','field_60c249d645c99'),(192170,6978,'contact_left_copy',''),(192171,6978,'_contact_left_copy','field_60c24a0845c9c'),(192172,6978,'display_right_column','1'),(192173,6978,'_display_right_column','field_613563f4d424c'),(192174,6978,'contact_right_heading',''),(192175,6978,'_contact_right_heading','field_60c249e945c9a'),(192176,6978,'contact_right_copy',''),(192177,6978,'_contact_right_copy','field_60c249f845c9b'),(192178,6978,'contact_right_cta',''),(192179,6978,'_contact_right_cta','field_60c24a1945c9d'),(192180,6978,'content_blocks_6_header','Pressure'),(192181,6978,'_content_blocks_6_header','field_6170d8ba9800b'),(192182,6978,'content_blocks_6_description','The pressure of the pump, measured in PSI, will determine cutting speeds for a given orifice size and number of heads. All other things being equal, there is an almost direct correlation between pressure and cutting speed; higher pressure results in higher cutting speeds. From a practical standpoint, increasing pressure also results in higher pump consumable costs, so that must be weighed against the faster cutting speeds.\r\n\r\nThe following graph shows the cutting speeds for ½” (12 mm) stainless steel for a Quality 2 edge finish. The two lines represent two common combinations of orifices and abrasive nozzles. In each case, doubling the pressure from 30,000 psi (2068 bar) to 60,000 psi (4137 bar) results in an increase in linear cutting speed of approximately 2.9 times.\r\n\r\n<b>IMPORTANT:</b> Keep in mind that pump horsepower is not always a direct indication of maximum pressure for the pump. A 200 HP pump may not necessarily have higher pressure than a 100 HP or 50 HP pump.'),(192183,6978,'_content_blocks_6_description','field_6170d8cd9800c'),(192184,6978,'content_blocks_6_images','1'),(192185,6978,'_content_blocks_6_images','field_6170d8df9800d'),(192186,6978,'content_blocks_6_images_0_image','2958'),(192187,6978,'_content_blocks_6_images_0_image','field_6170d8e99800e'),(192188,6978,'content_blocks_6_images_0_header',''),(192189,6978,'_content_blocks_6_images_0_header','field_6170d8f49800f'),(192190,6978,'content_blocks_6_images_0_description',''),(192191,6978,'_content_blocks_6_images_0_description','field_6170d90398010'),(192192,6978,'content_blocks_7_header','Water Output'),(192193,6978,'_content_blocks_7_header','field_6170d8ba9800b'),(192194,6978,'content_blocks_7_description','Water output, or flow rate, is a function of horsepower and pressure. A 50 HP intensifier pump running at 60,000 psi will generally have a maximum output of 1 gallon per minute (gpm). A 100 HP pump running at 60,000 psi will typically put out 2 gpm. This information will help you determine the maximum number of cutting heads that you can use with a pump. Different pump manufacturers will produce slightly different volumes. They may also specify a Maximum Output Pressure and an Operating Output Pressure with different associated water outputs. It is important to verify that the water output specified is what you can expect on a regular production basis (i.e. flow rate based off of Operating Output Pressure).'),(192195,6978,'_content_blocks_7_description','field_6170d8cd9800c'),(192196,6978,'content_blocks_7_images',''),(192197,6978,'_content_blocks_7_images','field_6170d8df9800d'),(192198,6978,'content_blocks_8_header','Orifice selection – The scientific way'),(192199,6978,'_content_blocks_8_header','field_6170d8ba9800b'),(192200,6978,'content_blocks_8_description','The Maximum Continuous Output Pressure and Maximum Output Flow from the “Pump Specifications” in Figure 1 are important in order to understand how many cutting heads you will be able to run with a pump. These numbers can be used in conjunction with the following “Flow Rate Through an Orifice” in Figure 2 to determine the number of cutting heads you can use.\r\n\r\n<b>Example 1</b>: 50 HP Pump, 1 Cutting Head, 60,000 PSI, 1.1 GPM water output\r\n<ol class=\"steps\">\r\n 	<li>If you were looking at the 50 HP pump, from the “Pump Specification” chart you would know that your pump puts out 1.1 gpm at 60,000 psi.</li>\r\n 	<li>You would look down under the “60” column (corresponding to the 60,000 psi pump) in the “Flow Rate” chart until you found a number equal to or less than 1.1. In this case, you would end up at the cell with 1.00.</li>\r\n 	<li>You would then follow that row across to the left to see the maximum size orifice you could use for single-head cutting. In this case, the cell shows that a 0.014” would be the maximum recommended orifice for one head at 60,000 psi.</li>\r\n 	<li>If you were in a tight spot where you only had a 0.015” orifice you might be able to use it by running the pump at 55,000 psi.</li>\r\n</ol>\r\nYou would be at the 1.1 gpm limitation of the pump. If there were any water leaks in your system between the pump and the cutting head, you would likely have a pump “over stroke” situation where the pump would try to cycle too fast attempting to create the required pressure. With modern pumps, there is no harm done if this happens. The pump is simply shut down to protect itself from damage and an error message is displayed for the operator.'),(192201,6978,'_content_blocks_8_description','field_6170d8cd9800c'),(192202,6978,'content_blocks_8_images','1'),(192203,6978,'_content_blocks_8_images','field_6170d8df9800d'),(192204,6978,'content_blocks_8_images_0_image',''),(192205,6978,'_content_blocks_8_images_0_image','field_6170d8e99800e'),(192206,6978,'content_blocks_8_images_0_header','chart needed here'),(192207,6978,'_content_blocks_8_images_0_header','field_6170d8f49800f'),(192208,6978,'content_blocks_8_images_0_description',''),(192209,6978,'_content_blocks_8_images_0_description','field_6170d90398010'),(192210,6978,'content_blocks_9_header','Running Two Cutting Heads'),(192211,6978,'_content_blocks_9_header','field_6170d8ba9800b'),(192212,6978,'content_blocks_9_description','<b>Example 2</b> 50 HP Pump, 2 Cutting Heads, 60,000 PSI, 1.1 GPM water output\r\n\r\nIf you wanted to run 2 cutting heads, then you would take the 1.1 gpm number, divide it by 2 for a maximum of 0.55 gpm per head. Look for the cell under 60 kpsi that has a number smaller than or equal to 0.55. In this case, under the “60” column you would end up in the 0.51 cell, meaning that one 0.010” orifice would put out 0.51 gpm. The maximum number of heads that you could run with the pump at 60 kpsi would be two (1.1 ÷ 2 = 0.55. 0.55 &gt; 0.51 = OK).'),(192213,6978,'_content_blocks_9_description','field_6170d8cd9800c'),(192214,6978,'content_blocks_9_images',''),(192215,6978,'_content_blocks_9_images','field_6170d8df9800d'),(192216,6978,'content_blocks_10_header','Orifice selection – the easy way'),(192217,6978,'_content_blocks_10_header','field_6170d8ba9800b'),(192218,6978,'content_blocks_10_description','Since the pump design engineers have done most of the hard math already, most users need only refer to an “Orifice Selection Chart” similar to the following, which is usually supplied by the pump manufacturer. Here you would quickly see that for the 50 HP pump, you could use either one 0.014” orifice or two 0.010” orifices.'),(192219,6978,'_content_blocks_10_description','field_6170d8cd9800c'),(192220,6978,'content_blocks_10_images_0_image',''),(192221,6978,'_content_blocks_10_images_0_image','field_6170d8e99800e'),(192222,6978,'content_blocks_10_images_0_header','insert table'),(192223,6978,'_content_blocks_10_images_0_header','field_6170d8f49800f'),(192224,6978,'content_blocks_10_images_0_description',''),(192225,6978,'_content_blocks_10_images_0_description','field_6170d90398010'),(192226,6978,'content_blocks_10_images','1'),(192227,6978,'_content_blocks_10_images','field_6170d8df9800d'),(192228,6978,'content_blocks_11_header','General pump selection guidelines'),(192229,6978,'_content_blocks_11_header','field_6170d8ba9800b'),(192230,6978,'content_blocks_11_description','The next step in determining which pump is appropriate for your application is to determine the types of material you will be cutting and how many cutting heads you want to be able to run at one time.\r\n\r\nIf you are cutting parts out of foam, wood, cardboard or other soft materials, then you would be dealing with a pure water application. For pure water applications, a 30 HP pump is usually sufficient. As you can see from the previous Orifice Selection chart, up to three cutting heads could be used with 0.006” orifices.\r\n\r\nIf more cutting heads were needed, then a 50 HP pump could handle up to five cutting heads with 0.006” orifices. For abrasive applications, the 50 HP is the general starting point. With this pump, you can run one head with a 0.014” orifice or two heads with 0.010” orifices. The 0.010” orifice will perform exceptionally well with respect to speed and cut quality on thinner material (1/2” and under).\r\n\r\nThe following graph shows cutting speeds for single head versus dual head cutting in ½” stainless steel. As thickness get beyond 2” (50 mm), the absolute difference in cutting speeds between the nozzle combinations starts to decrease more dramatically.\r\n\r\nCutting with two heads with 0.010” orifices effectively doubles the cutting speed (2 x 5.5 ipm) versus cutting with one head with a 0.010” orifice. Compared to cutting with one head with the 0.014” orifice, cutting with two heads will increase output by about 20 percent. To put this concept into real world terms, it would be like if you started cutting on a job on Monday morning with two cutting heads, then you could get it to your customer by Thursday afternoon. If you cut the job with one head, your customer wouldn’t get the part until Friday afternoon.\r\n\r\nFor someone looking to cut thicker materials on a consistent basis, then we would suggest allocating 50 HP per cutting head. If you selected a 100 HP pump, you could run two heads with 0.014”.\r\n\r\nIf you are cutting very small parts in high volumes, you might want a very large cutting table where you could run four cutting heads and quadruple your production over a single-headed system. In that case you would likely choose the 150 HP pump that can run four heads with 0.013” orifices.'),(192231,6978,'_content_blocks_11_description','field_6170d8cd9800c'),(192232,6978,'content_blocks_11_images_0_image','2960'),(192233,6978,'_content_blocks_11_images_0_image','field_6170d8e99800e'),(192234,6978,'content_blocks_11_images_0_header',''),(192235,6978,'_content_blocks_11_images_0_header','field_6170d8f49800f'),(192236,6978,'content_blocks_11_images_0_description',''),(192237,6978,'_content_blocks_11_images_0_description','field_6170d90398010'),(192238,6978,'content_blocks_11_images','1'),(192239,6978,'_content_blocks_11_images','field_6170d8df9800d'),(192240,6978,'content_blocks_12_header','Abrasive nozzle selection'),(192241,6978,'_content_blocks_12_header','field_6170d8ba9800b'),(192242,6978,'content_blocks_12_description','As a general rule, the diameter of the orifice for the abrasive nozzle should be approximately three times the water nozzle orifice.\r\n\r\nSome people would suggest using a smaller ratio, about 2.5 times. Using a smaller ratio does produce faster cutting speeds. The trade-off is increased nozzle wear and costs. Part tolerance will suffer because of the increased speed of nozzle wear.\r\n\r\nFollowing is a quick reference guide for the most common orifices for abrasive waterjet cutting. Typical abrasive amounts and water flow are also shown for easy reference.'),(192243,6978,'_content_blocks_12_description','field_6170d8cd9800c'),(192244,6978,'content_blocks_12_images_0_image',''),(192245,6978,'_content_blocks_12_images_0_image','field_6170d8e99800e'),(192246,6978,'content_blocks_12_images_0_header','insert chart'),(192247,6978,'_content_blocks_12_images_0_header','field_6170d8f49800f'),(192248,6978,'content_blocks_12_images_0_description',''),(192249,6978,'_content_blocks_12_images_0_description','field_6170d90398010'),(192250,6978,'content_blocks_12_images','1'),(192251,6978,'_content_blocks_12_images','field_6170d8df9800d'),(192252,6978,'content_blocks_13_header','Abrasive amount and cutting speeds'),(192253,6978,'_content_blocks_13_header','field_6170d8ba9800b'),(192254,6978,'content_blocks_13_description','In Chapter 1, “Cutting Characteristics,” under the section “Creation of the abrasive waterjet stream”, we discussed how the abrasive waterjet stream is created. The cross-section of the cutting head is shown again here.\r\n\r\n<img class=\"size-medium wp-image-6973 aligncenter\" src=\"http://www.wardjet.com/wp-content/uploads/2022/03/closeup-of-waterjet-cutting-head-300x225.jpg\" alt=\"closeup-of-waterjet-cutting-head\" width=\"450\" />\r\n\r\n&nbsp;\r\n\r\nAs abrasive is added to the waterjet stream, the abrasive particles are accelerated to near the speed of the waterjet, approximately 2200 miles per hour (almost three times the speed of sound). This speed imparts momentum to the abrasive particles so that they can erode the material. Adding more abrasive gives more energy to the process and erosion occurs faster. Eventually a saturation point occurs where adding more abrasive robs speed and power from the waterjet stream and cutting speeds will start to decrease. Each waterjet manufacturer goes through extensive testing with various orifice and nozzle combinations to find the optimum abrasive amount, balancing cost and cutting speed.\r\n\r\nThe following graph shows what happens to cutting speed for ½” stainless steel as abrasive is added. Speeds are shown for the two most common orifice/abrasive nozzle combinations, 0.010” orifice with a 0.030” abrasive nozzle (orange line) and 0.014” orifice with a 0.040” abrasive nozzle (blue line).\r\n\r\nStarting with an abrasive flow of zero pounds per minute, there would be absolutely no penetration of the material except for maybe a very light etching of the top surface of the material. At this point cutting speed is zero. Cutting speed increases as more and more abrasive is added. For the larger nozzle combination, speed increases until around 1.5 pounds per minute. At this point, cutting speed starts to decrease as too much kinetic energy is removed from the waterjet stream by the abrasive. A similar thing happens with the smaller orifice/nozzle combination, but at slower speeds and lower abrasive amounts.\r\n\r\n<img class=\"size-full wp-image-2961 aligncenter\" src=\"http://www.wardjet.com/wp-content/uploads/2021/11/Waterjet-University_Nozzle-n-Orifice-Abrasive-Amount-and-Cutting-Speed-Chart.jpg\" alt=\"Waterjet University_Nozzle n Orifice Abrasive Amount and Cutting Speed Chart\" width=\"617\" height=\"343\" />\r\n\r\n&nbsp;\r\n\r\nThe optimum cost point may be slightly below what looks to be the apex of the speed curve. The “Law of Diminishing Returns” becomes evident. As the maximum speed is approached, each additional unit of abrasive that is added results in an ever smaller increase in speed. In the case of the orange line, increasing the abrasive from 0.7 pounds per minute to 1.0 pounds per minute yields an increase in speed of only 0.2 inches per minute. This 3.6% increase in speed results in a 4.7% increase in cost per inch.'),(192255,6978,'_content_blocks_13_description','field_6170d8cd9800c'),(192256,6978,'content_blocks_13_images',''),(192257,6978,'_content_blocks_13_images','field_6170d8df9800d'),(192258,6978,'content_blocks_14_header','Speed and efficiency of nozzle combinations'),(192259,6978,'_content_blocks_14_header','field_6170d8ba9800b'),(192260,6978,'content_blocks_14_description','We can see in the following graph that larger orifice/abrasive nozzle combinations will cut faster than smaller combinations. With the larger nozzle combination, virtually all of the pump’s power is used, so it will cut faster. The smaller orifice/nozzle cuts slower because less total power from the pump is used.\r\n\r\n<img class=\"size-medium wp-image-6977 aligncenter\" src=\"http://www.wardjet.com/wp-content/uploads/2022/03/nozzle-and-orifice-abrasive-amount-chart-2-300x172.jpg\" alt=\"nozzle and orifice - abrasive-amount-chart-2\" width=\"630\" />\r\n\r\n&nbsp;\r\n\r\nSmaller orifice/nozzle combinations are more efficient though in their use of water and abrasive. The available power of the waterjet is concentrated into a smaller area, so more power is directed to the cut.\r\n\r\n<img class=\"size-full wp-image-2962 aligncenter\" src=\"http://www.wardjet.com/wp-content/uploads/2021/11/Waterjet-University_Nozzle-n-Orifice-Nozzle-Combination-Chart-2.jpg\" alt=\"Waterjet University_Nozzle n Orifice Nozzle Combination Chart 2\" width=\"630\" height=\"418\" />\r\n\r\n&nbsp;\r\n\r\nIn the picture above, the diameter of the larger waterjet stream on the right is 33% wider and the area of this diameter is 78% greater. This makes the energy density lower than the smaller orifice/nozzle combination. The result is that, as shown earlier and repeated in the graph below, cutting with two 0.010”/0.030” heads is more cost-effective and productive than cutting with one 0.014”/0.040” head in thinner materials (approximately ½” and thinner).\r\n\r\n<img class=\"size-full wp-image-2963 aligncenter\" src=\"http://www.wardjet.com/wp-content/uploads/2021/11/abrasive-amount-chart-4.jpg\" alt=\"\" width=\"600\" height=\"351\" />'),(192261,6978,'_content_blocks_14_description','field_6170d8cd9800c'),(192262,6978,'content_blocks_14_images',''),(192263,6978,'_content_blocks_14_images','field_6170d8df9800d'),(192264,6978,'content_blocks_15_header','Nozzle wear'),(192265,6978,'_content_blocks_15_header','field_6170d8ba9800b'),(192266,6978,'content_blocks_15_description','As the abrasive nozzle wears, the diameter of the abrasive waterjet stream increases. The diameter increases by approximately 0.0001” per hour of cutting. Power per square inch is reduced. Therefore, the feed rate must be reduced in order to maintain the same edge finish, or the quality of the edge will deteriorate.'),(192267,6978,'_content_blocks_15_description','field_6170d8cd9800c'),(192268,6978,'content_blocks_15_images',''),(192269,6978,'_content_blocks_15_images','field_6170d8df9800d'),(192270,6978,'content_blocks_16_header','Cutting speed calculators'),(192271,6978,'_content_blocks_16_header','field_6170d8ba9800b'),(192272,6978,'content_blocks_16_description','Various waterjet feed rate calculators are available online. With these calculators, you can play around with the various parameters to see how cutting speed and cost per inch are affected. Below is an example of one such calculator.\r\n\r\nWith all of these calculators, it is more important to focus on cost per inch (or foot, or meter), rather than cost per hour. Focusing on cost per foot takes into account the diminishing returns discussed in the previous section.\r\n\r\nAnother thing to keep in mind is that these calculators are only showing straight line cutting speeds. Depending upon part geometry, piercing times, machine design and more, actual part cutting times can vary significantly from just taking the total linear inches of cutting in a part and dividing that number by the inches per minute shown in a calculator. The calculators are useful though in at least getting an idea of speeds and costs.'),(192273,6978,'_content_blocks_16_description','field_6170d8cd9800c'),(192274,6978,'content_blocks_16_images_0_image','2965'),(192275,6978,'_content_blocks_16_images_0_image','field_6170d8e99800e'),(192276,6978,'content_blocks_16_images_0_header',''),(192277,6978,'_content_blocks_16_images_0_header','field_6170d8f49800f'),(192278,6978,'content_blocks_16_images_0_description',''),(192279,6978,'_content_blocks_16_images_0_description','field_6170d90398010'),(192280,6978,'content_blocks_16_images','1'),(192281,6978,'_content_blocks_16_images','field_6170d8df9800d'),(192282,6978,'content_blocks_17_header','Machinability Index'),(192283,6978,'_content_blocks_17_header','field_6170d8ba9800b'),(192284,6978,'content_blocks_17_description','The Machinability Index shown in most waterjet feed rate calculators defines the relative cutting rates of different materials. Materials with higher numbers cut proportionately faster than lower numbers. Mild steel has a baseline value of one. Stainless steel at 0.9 would indicate that it cuts about 10% slower than mild steel to achieve similar edge quality and tolerance results.\r\n\r\nIf you know the machinability indexes of two materials, you can estimate fairly easily a good cutting speed of one material from the other. We know that the Machinability Index of stainless steel is 0.9 and below we see that Aluminum’s Machinability Index is 2.9. You know that ½” stainless cuts at 5.5 ipm for the edge quality you want. You want to know the speed for ½” Aluminum. Divide the machinability of Aluminum by the machinability of stainless. 2.9 ÷ 0.9 = 3.2. Multiply the cutting speed for Stainless by 3.2 for the cutting speed in the same thickness of Aluminum. 5.5 ipm x 3.2 = 17.6 ipm. Therefore, 17.6 ipm would be a good place to start for ½” Aluminum.'),(192285,6978,'_content_blocks_17_description','field_6170d8cd9800c'),(192286,6978,'content_blocks_17_images_0_image','2966'),(192287,6978,'_content_blocks_17_images_0_image','field_6170d8e99800e'),(192288,6978,'content_blocks_17_images_0_header',''),(192289,6978,'_content_blocks_17_images_0_header','field_6170d8f49800f'),(192290,6978,'content_blocks_17_images_0_description',''),(192291,6978,'_content_blocks_17_images_0_description','field_6170d90398010'),(192292,6978,'content_blocks_17_images_1_image','2967'),(192293,6978,'_content_blocks_17_images_1_image','field_6170d8e99800e'),(192294,6978,'content_blocks_17_images_1_header',''),(192295,6978,'_content_blocks_17_images_1_header','field_6170d8f49800f'),(192296,6978,'content_blocks_17_images_1_description',''),(192297,6978,'_content_blocks_17_images_1_description','field_6170d90398010'),(192298,6978,'content_blocks_17_images','2'),(192299,6978,'_content_blocks_17_images','field_6170d8df9800d'),(192300,6978,'content_blocks_18_header','Summary'),(192301,6978,'_content_blocks_18_header','field_6170d8ba9800b'),(192302,6978,'content_blocks_18_description','In this chapter we looked at the three critical specifications of a high pressure pump: horsepower, pressure and water output. We reviewed how to figure out what size orifice to use based upon these pump specifications and how many cutting heads are being used. We covered the productivity increases and cost savings of using two smaller orifices versus one large orifice. Additionally, abrasive nozzle diameter selection was discussed in terms of the ratio to the orifice being used. 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