Ultra High Pressure Waterjet Cutting Defects, Maintenance and Safety
In todays world, ultra high pressure waterjet cutting is used for a variety of tasks, ranging from simple cutting and drilling to complex industrial applications. Not only does this particular cutting process offer the greatest flexibility possible for cutting through different types of materials, but it also is relatively fast and cost-effective. However, with such intense waterjet cutting pressure, there is a risk of causing damage or even creating safety hazards. In order to ensure the safety of personnel, property and products, it is important to be knowledgeable and understand the associated risks as well as common ultra high pressure waterjet cutting defects.
Ultra high pressure waterjet cutting (commonly referred to as UHPWJ or UHP waterjet) is a cutting process that uses extremely high pressure—up to 60,000 psi—to slice and cut various types of materials. While this type of cutting process provides precision, accuracy, and speed compared to traditional methods, it also carries certain risks depending on the type of material being cut, the volume of water and pressure being used, the distance of the cutting head from the target, etc.
The most common UHPWJ defect is cracking. Cracking is caused by stress introduced during the cutting process by the intense pressure and torsion of the waterjet’s flow. As the material begins to be cut, sections of the material can crack due to the unequal stress from the surrounding part. This is especially common among brittle materials such as glass, ceramics, and composites.
During the UHPWJ process, the width of the cut can also vary or be distorted due to delicate materials such as plastics, foams, and metals. When the waterjet hits the material, the material can be displaced and shifted around the cutting path, which results in a distorted and uneven cut.
While UHPWJ has the capability to cut through a variety of materials at high speed, it can also cause gouging and burring when used improperly. If the cutting is too slow, or the dwell time is too long, the waterjet can cause deep gouges, scores, and burrs. These defects usually originate from improper cutting speeds, an inadequate nozzle, or a fault in the cutting program.
On the other hand, if the cutting speed is too fast and the pressure is too low, inadequate heat and excessive wear can occur, resulting in stressed material and discoloration of the material’s surface.
In order to achieve the best results with UHPWJ, proper maintenance and safety protocols must be followed. Equipment should be regularly inspected and maintained in order to maintain the quality of the equipment and to ensure it is running properly. If any problems arise, they should be immediately addressed by a qualified technician. In addition, a training program should be implemented for all personnel operating the equipment. This ensures that all personnel have a proper understanding of how to safely operate the equipment and recognize any potential hazards, as well as how to address any potential waterjet-cutting defects.
Lastly, personal protection equipment (PPE) should be worn when operating the waterjet. Goggles, masks, coveralls, and steel-toed boots are all necessary safety accessories to wear while operating the UHPWJmachine. Proper safety precautions go a long way in minimizing potential risks and ensuring the safety of everyone in the working environment.
In conclusion, ultra high pressure waterjet cutting is a versatile and effective cutting technology that can provide immense benefits when operated correctly. However, due to the intense pressures and torsion generated by the waterjet, a high degree of care is necessary in order to avoid the common defects that can arise. Strict maintenance and safety protocols must be followed in order to operate the waterjet correctly and safely, and all personnel must be properly trained in UHPWJ cutting and safety.
