Waterjet Cutting: Everything You Should Know

Have you ever heard of waterjet cutting? It is a versatile cutting method that helps manufacture components for multiple applications. It can shape and carve material in a unique way.

If you are inclined to learn more about what is waterjet cutting, let's read the guide below.

What is Waterjet Cutting?

Waterjet cutting is a process that uses water at high pressure to cut the material.

The process consists of passing the stream of water with some abrasive particles at a very high speed. This stream is directed towards the path of materials that are meant to be cut.

Waterjet cutting doesn't generate heat. It is suitable for working with different materials without altering their properties.

How Does Waterjet Cutting Work？

The process of waterjet cutting has some basic steps, which are given below:

• Pressurization is the first stage in which water is generated with high pressure with the help of special pumps, and the pressure of water reaches 90000 psi.
• In cases where abrasive waterjet cutting is required, abrasive particles like garnet sand are mixed with the water in a mixing chamber which improves the capability of the process.
• When the water with high pressure and abrasive mixture is directed towards the material with the help of a nozzle, the detailed and precise shapes are cut with the help of the cutter’s precision.
• The material that is opted for cutting is placed on a table that offers support during the cutting process.
• There is a catcher tank that catches the water and abrasive particles so that waste management can be effectively carried out.

Benefits of Waterjet Cutting

The process of waterjet cutting has various benefits, some of these are as follows:

• It is a cold cutting process and hence does not produce any heat, which ensures that the structural integrity of the workpiece is maintained.
• Waterjet cutting is opted for a wide range of materials, including ceramics, glass, plastics, and even stones, which allows the process to suit every type of application.
• Waterjet cutting offers highly precise cuts and tight tolerance in the components. Hence, industries like aerospace, which require accuracy in components, may find this process suitable.
• The cuts achieved by waterjet cutting ensure smooth edges, and this reduces the need for surface finishing and saves time as well as cost.
• Waterjet cutting does not release any harmful emissions and, hence, is safe for the operators as well as the environment.
• Complex shapes and components with high functionality can easily be created through waterjet cutting.

Types of Waterjet Cutting

There are different types of waterjet cutting, and these are the following:

Abrasive Waterjet Cutting

Abrasive waterjet cutting involves using high-pressure water and garnet sand particles mixed together to create abrasion.

This mixture is then passed through the nozzle, which creates a powerful stream of water that passes through the workpiece so that it can be cut down to the required shape and precision.

The process of abrasive waterjet cutting is opted mostly for cutting materials that are hard. This is usually used in aerospace to manufacture structural components and turbine blades.

Pure Waterjet Cutting

Pure waterjet cutting involves cutting through high-pressure water, which is passed through a nozzle and creates a stream of water with high velocity. It is a thin stream that can cut soft materials with high accuracy.

The process of pure waterjet cutting is used in manufacturing packaging foams, in the textile industry, and in cutting gaskets.

Abrasive Jet Machining

Abrasive jet machining is a process of machining in which abrasives are released at a high velocity with the help of gas, which helps cut the workpiece material as required.

It is used in materials that are thin and brittle and helps in making specific edge shapes.

High-Pressure Water Cutting

High-pressure waterjet cutting allows them to pass the high-pressure water with a nozzle in the mixing chamber.

The pressure then creates a vacuum drawing sand in the stream, which is then fired to the workpiece.

CNC Waterjet Cutting

CNC waterjet cutting has an automated cutting machine that has waterjet cutting technology using high-pressure water.

The CNC programs are created, and the machine works according to them, creating highly precise cuts.

Suitable Materials for Waterjet Cutting

The materials suitable for waterjet cutting are versatile, and some of these are the following:

Metals

Waterjet cutting is used to cut metals effectively, ensuring that precision and neat edges are achieved.

The different types of metals that can be opted for in the process of waterjet cutting include steel, aluminum, brass, titanium, and copper.

The best part about waterjet cutting is that it doesn't produce heat, and hence, the metal workpiece stays intact.

Ceramics and Stones

Stones and ceramic workpieces are also used for certain components through waterjet cutting.

These materials offer the ability to create complex and precise designs. The commonly adopted stones and ceramics are granite, marble, tiles, and composite stones.

Glass

Glass of different types like tempered glass, laminated glass and optical glass are also cut through waterjet cutting.

The process is safe for glass cutting because it does not cause any thermal stress and hence prevents it from cracking.

Plastics and Composites

Plastics and composites can also be cut very effectively through waterjet cutting.

Waterjet cutting plastics ensures that smooth edges and accuracy in shapes is achieved.

Some of these plastics and composites are polycarbonate, acrylics, carbon fiber and fiberglass.

Apart from these textiles, wooden material and some foods are also cut through waterjet cutting due to its suitability for versatile applications.

Applications of Waterjet Cutting

The process of waterjet cutting is observed in various industries, and some of these applications are discussed below:

Automobile Industry

The automobile industry requires parts of vehicles that are complex and need precision.

Waterjet cutting is a process that allows the creation of custom panels for dashboards, interior trims, and engine components.

The process can use a wide range of composites, plastics, and metals, which are needed in the automobile industry.

Aerospace Industry

The aerospace industry needs components that are manufactured using aluminum and titanium due to their excellent strength-to-weight ratio.

Waterjet cutting helps create components made using these materials, which include turbine blades and other structural parts. The process ensures that seamless edge quality is attained.

Electronics Industry

Waterjet cutting allows the manufacture of circuit boards and other components used in electronics. It ensures that clean cuts are achieved without damaging the materials used in production.

Construction Industry

In the construction industry, the need to cut stones, tiles, and concrete is quite common, and achieving custom shapes for architectural items and flooring is required.

Waterjet cutting helps to achieve these shapes with high accuracy and smooth edges.

Comparing Cutting Technologies

Waterjet cutting can be compared to some other cutting technologies, and such a comparison is shown below.

Waterjet Cutting vs Laser Cutting

Waterjet cutting uses a high-pressure stream of water, which has abrasives in order to cut the materials, and no heat is generated. It is suitable for cutting different materials, thick, thin, and reflective.

Meanwhile, laser cutting uses a laser beam that melts the material, and it is mostly opted for thinner materials that are non-metallic.

Waterjet Cutting vs. EDM Machining

Waterjet cutting is a method that can help cut the materials with no heat generation, and hence, the components are protected from deforming or losing their structural integrity.

EDM is also a very precise process, but it uses electricity to cut the materials and create sparks.

EDM is mostly used for complex shapes, but the materials it can work with are mostly conductive ones.

Waterjet Cutting vs. Plasma Cutting

Waterjet cutting, being a cold-cutting process, can work with multiple materials with no fumes and thermal distortion.

At the same time, plasma cutting uses ionized gas, which melts the material that is electrically conductive.

The process of plasma cutting is limited to thick metals only, and due to the heat generated, it can lead to the oxidation of the material.

Conclusion

Waterjet cutting offers exceptional versatility and benefits. It is suitable for a wide range of materials and doesn't even release heat.

If you are also looking for high-quality waterjet cutting services, DEK is your go-to manufacturer. We offer waterjet cutting services for any custom components using different materials.

FAQs

Is waterjet cutting better than laser?

Laser cutting is faster and more precise than waterjet cutting, but it generates heat, which causes the materials to deform if care is not taken.

Hence, laser cutting is only suitable when exceptional precision is needed.

What are the disadvantages of waterjet cutting?

Waterjet cutting is a time-consuming process, and in cases where the water pressure is inconsistent, the required accuracy cannot be attained.