Waterjet Optimization Tips

Operators are the most critical component in the abrasive waterjet cutting process. A machine is only as productive as its operator, so the better trained he or she is, the more s/he can operate a machine to its maximum performance. Operators should be trained extensively and on a continuous basis, which is more easily accomplished by working with those waterjet machine suppliers that offer free training.

On the hardware side, waterjet machines are basically just pumps, nozzles and worktables. It is the control software that is the key to truly optimizing a machine’s performance in terms of speed and efficiency. Shops should make sure their waterjet systems include the most powerful and effective software. With that said, it is most advantageous for shops to work with machine suppliers that continually advance their software and offer free upgrades once new versions are available. Those shops that don’t have access to software upgrades will definitely lose out on potential increased machine productivity.

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Level of capability will contribute directly to a waterjet machine’s performance and productivity. For instance, the capability to monitor changes in workpiece material surfaces or thicknesses and automatically adjust for them will eliminate the risk of machine damage if an operator momentarily steps away from the machine. Plus, such a function allows for continuous uninterrupted machine operation.

Another is the capability of a machine to actively control taper. This type of function would automatically adjust for the naturally occurring taper of a waterjet stream. Other performance enhancing capabilities include 5-axis and rotary axis machining, which allow shops to increase their part cutting diversity. Thus, machines gain the ability to process a wider range of part types to further increase their productivity potential.

It should be noted that no matter what the waterjet machine’s current capability or functionality, it is most beneficial to have the option to add such systems to existing machines. When machine suppliers make these systems retrofitable, they enable shops to keep machines producing to their full potential – even if they happen to be older models – and do so cost-effectively.

When it comes to selecting a waterjet table size, most machine suppliers suggest first evaluating parts intended to be cut on the machine – whether existing jobs or those being considered for the future. A common rule of thumb is to reference the largest part a shop produces or the biggest size sheet material with which it works as a starting point and select a machine table size accordingly.

Prior to even installing an abrasive waterjet machine, shops should have their water tested. This will help determine if certain actions need to be taken, such as adding water filters or chillers to ensure that the machine operates with only the highest quality water. It is often recommended and quite convenient to locate waterjet machines close to drains, as well as water sources within the shop.

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For optimum performance, waterjet machines must be kept well maintained and in perfect operating condition. Certain machine control functions offered by some machine suppliers can make maintenance easier and more proactive, as opposed to reactive. Such functions include forms of maintenance management software that monitor machine components for wear and indicate when preventative maintenance is required.

With this monitoring ability, shops eliminate unexpected down time through preventative maintenance, as opposed to only doing so when something breaks and the machine is down.

Successful shops understand that a clean and well-maintained workspace is key to maximizing productivity. The workspace extends to the machinery. With abrasive waterjet machines, it extends to the tank. We’ve gathered  ve best practice tips to keep your abrasive waterjet tank in top condition and your production running at peak effciency.

The slats that support the material in your abrasive waterjet erode over time and will eventually need to be replaced. You can greatly extend the working life of your removable slats by periodically rotating them. The slats can be flipped horizontally, flipped vertically, or moved to a different area of the table. Create a schedule to inspect and rotate the slats at least once a month. Any weakened and worn slats should be replaced. When replacing a defective slat, also inspect the slat holder for excessive wear. Worn slat holders should also be replaced. New sets of galvanized steel slats can be ordered directly from OMAX.

One big advantage of cutting under water is that it dramatically reduces noise. It also prevents abrasive and material particles from splashing on machine components and the work area. This helps keep the work environment clean and extends the life of the machine’s components. Cutting under water can also reduce or eliminate the surface “frosting” that can appear on the top edge of a cut. One more, somewhat counterintuitive benefit to cutting under water is that parts rust less when submerged. Being under water prevents the constant splash of water, then air, then water, and then air, which accelerates the rusting process.

Since abrasive and metal particles are constantly accumulating in the tank, it is necessary to remove the accumulated waste deposits on a regular basis. When large quantities of abrasive particles quickly settle on the material being machined, it is usually a good indicator that too much waste material is being held in the tank and that waste needs to be removed. If you are removing abrasive material from the bottom of the tank by hand, it is best to drain water from the tank completely first. The drier the abrasive, the easier it shovels out. Using a pointed shovel is probably the most effective way of emptying the tank by hand. The OMAX Variable Speed Solids Removal System (VS-SRS) is an effective alternative to manually cleaning the tank.

If you are using a Variable Speed Solids Removal System with your abrasive waterjet tank, you can greatly enhance the system’s effectiveness by running the tank cleaning program in OMAX MAKE. this program runs a stream of water back and forth across the entire table, agitating abrasive and material waste that tends to collect in piles on the bottom of the waterjet tank. The VS-SRS can then efficiently remove the circulating waste particles from the tank.

To verify the pump and nozzle are working correctly, conduct tests on a regular basis. These tests should typically be performed following nozzle maintenance, after clearing a plugged nozzle, or at the start of the day to verify proper operation. The stream from a waterjet is powerful enough that it will eventually cut a hole in almost anything in its way, including the floor of the tank. When testing the nozzle, frequently change the location along the table where you run the tests to avoid piercing through the tank.