Waterjet is a high-tech CNC waterjet cutting machine that enables precise processing of a wide range of materials - from plastics and food to extremely hard materials, such as metal, and brittle materials, which include glass and ceramic products. One of the main advantages of this technology is the ability to process materials as thick as 250 mm, which is a significant advantage over, for example, laser technology. It is a so-called non-thermal method, using a jet of water at extremely high speed to separate the material. There are two basic methods of cutting using waterjet machines:

• Clean water cutting - used for soft materials such as rubber, plastic and plywood.
• Waterjet cutting with an abrasive (such as garnet) - for harder materials such as metals, glass, stone or carbon fiber.

The cutting process is carried out by injecting water under tremendous pressure, reaching up to 6,000 bar, and directing it onto the surface of the workpiece. The erosion force generated by the jet results in effective separation of the material's structure without thermal influence, eliminating the risk of deformation and scorching.

1. Main advantages of waterjet cutting over other technologies

First of all, versatility

Waterjet cutting is characterized by virtually no material restrictions - both very thin and very thick materials can be processed with this method, making it far superior to other technologies.

An unquestionable advantage of waterjet cutting technology is its versatility in terms of the type of materials that can be processed. This method allows precise cutting of almost all materials, such as aluminum, steel, stone, plywood, rubber, plastic, foam and even food. As a result, waterjet cutting is used in a variety of industries, offering a fast, economical and environmentally friendly solution.

 

So what materials can be cut with waterjet technology?

Metals

Waterjet cutting is one of the most versatile methods for machining almost all types of metals, including aluminum, steel, iron and titanium. One of its key advantages is its non-thermal nature - the cutting process does not generate heat, so the material does not overheat or deform, and no scorch marks appear on the surface. In addition, the water jet with an abrasive agent allows effective cutting of even the hardest materials, such as titanium or steel.

Glass and ceramics

Water jet cutting is a precise and efficient method of processing glass, allowing it to cut holes, edges and complex shapes without the risk of cracks or damage. The use of a high-pressure water jet, often with the addition of an abrasive, results in perfectly finished parts with smooth edges, without the need for additional processing. One of the key advantages of this technology is the absence of thermal effects, which eliminates the risk of micro-cracks and deformation. In addition, it minimizes material losses, making it an economical and ecological solution.

Timber and paper

One of the biggest advantages of waterjet wood cutting is scorch-free cutting, which preserves the natural surface of the material without signs of burning or delamination. The tools used in this method do not wear out, especially when only water jet is used, without the addition of abrasives. This makes versatile use of the technology possible without the need for frequent tool changes. When cutting paper products, cardboard or thin plywood, the high-pressure water jet is very thin - usually thinner than when cutting stone or metal. This allows for exceptional precision and accuracy in cutting.

Stone and tiles

Water jet cutting is a commonly used method for processing stone and tile. With appropriately selected parameters, it allows precise cutting of holes, edges and complex shapes without the risk of deformation or damage to the material.

The use of abrasive water jet allows fast and economical cutting, and thanks to the low-pressure piercing technology, the material does not break and its surface remains intact. The minimal cutting width allows for smooth edges, eliminating the need for additional machining.

Plastics, rubber, composites

When cutting plastics and rubber with a waterjet, it is necessary to first determine the required cutting quality and thickness of the material to select the appropriate method - abrasive or pure waterjet. This process does not cause structural changes in the material, and with it you can cut a variety of shapes without changing tools.

Water jet cutting is also an environmentally friendly solution, as it does not generate harmful gases or chemicals. In the case of composite materials, the properties of the individual layers must be taken into account. With properly selected parameters, this technique allows for precise cutting of both shapes and holes.

Wide possibilities: complex patterns, routing and beveling

Water jet cutting machines enable precise processing of materials, making very narrow cuts with excellent edge quality. This allows designers to create intricate parts that would be virtually impossible with traditional manufacturing processes.

Waterjet technology allows for complex shapes and contours, as well as the cutting of intricate patterns. In addition, thanks to 3D (5-axis) cutting, routing and beveling are possible, which significantly expands the range of available geometries.

Water jet cutting also offers the possibility of stack cutting, which increases productivity and allows efficient use of material. Another advantage is the wide range of shapes and sizes that can be achieved without changing the cutting tool set.

Waterjet cutting - precision without the influence of heat.

The waterjet cutting method - Waterjet - is a modern material processing technology that does not generate high temperatures at the cutting site, which eliminates the risk of thermal deformation and structural changes in the material. This makes the process extremely precise and safe even for the most demanding parts.

One of the key advantages of Waterjet cutting is the ability to meet stringent dimensional tolerance requirements. In many cases, additional finishing is not necessary, as the product obtained directly from the cutting table is characterized by high edge quality. The method produces sharp angles and cuts with a minimum of burrs, although in the case of very complex parts a small correction may be needed.

Waterjet is ideal for cutting glass and ceramics, allowing precise cutting of holes and shapes. It is worth noting, however, that in the case of ceramics, it is necessary to properly select the cutting parameters to avoid cracking of the material. In glass cutting, it is crucial to use the right pressure and abrasive granulation to minimize the risk of damage.

For wood and paper, waterjet technology does not emit harmful substances such as chemicals, fumes or smoke, making it an environmentally friendly and safe solution. However, it should be taken into account that the water used in the process may contain fine organic residues, which require proper treatment.

The lack of mechanical friction means that the only contact factor is the abrasive waterjet, which eliminates the risk of damage from tool-to-material contact. What's more, the Waterjet method reduces the need for further machining, and its precision makes it easy to carry out additional processes, such as threading, without the risk of altering material properties.

Thanks to these characteristics, waterjet cutting is widely used in various industries, offering high quality, precision and minimized material loss.

Easy, eco-friendly solution

Waterjet cutting is a modern and ecological processing method that requires only electricity and water, and in the case of extremely hard materials, the addition of an abrasive. The process minimizes the emission of harmful substances, and all dust and impurities can be effectively filtered from the water, making it safe for the environment. This makes waterjet the ideal solution for companies striving for sustainable production, combining precision cutting with environmental responsibility.

2. Automation of waterjet cutting on CNC waterjet machines - modern software

Modern CNC waterjet machines are distinguished by a high degree of automation, which translates into increased efficiency and cutting precision. Thanks to advanced control systems, autonomous cutting with minimal operator supervision is possible, which in many cases eliminates the need for additional finishing.

One of the key aspects of process optimization is the efficient placement of parts on the sheet - so-called nesting, which, together with a thin cutting gap, minimizes material loss. This efficiency also depends on the type of raw material being processed and the quality of the placement algorithms. What's more, waterjet machines allow simultaneous cutting of multiple layers of homogeneous materials, such as rubber or composite fibers, which significantly increases production efficiency.

An important development in waterjet cutting technology is the use of numerically controlled abrasive dispensing systems. They enable precise control of the amount of abrasive supplied to the cutting head, which ensures high quality and repeatability of the process. In addition, state-of-the-art cutting angle compensation algorithms at maximum feed speed reduce errors associated with cutting taper and improve edge finish quality.

Thanks to the use of advanced software, CNC waterjet machines are becoming increasingly efficient, precise and economical. They are used in a wide range of industries, such as aviation, automotive and glass, where high quality machining and minimizing material loss are key.

3. Waterjet machine - how does it work?

The waterjet machine uses extremely high-pressure water jet cutting technology. Water is brought to a pressure as high as 6,000 bar and passed through a nozzle with a very small diameter, which allows for a coherent jet of liquid with a speed exceeding three times the speed of sound.

Cutting process

Water, under very high pressure (up to 6,000 bar), is directed at the material to be cut. For harder materials, such as steel or ceramics, the abrasive waterjet method is used, in which an abrasive - usually garnet, a very hard mineral with sharp edges - is added to the water. The abrasive is introduced into the waterjet through the Venturi effect in a mixing chamber, where it is thoroughly mixed with the liquid. The jet is then formed and stabilized in the hydro-abrasive nozzle, reaching speeds as high as 900 m/s.

Waterjet technology works well with both soft materials (e.g., rubber, foam) and very hard materials (e.g., titanium, ceramics). In the case of brittle materials, such as glass or ceramics, the cutting process is slower, and piercing the surface requires more care to avoid damage. By using waterjet cutting technology, it is possible to precisely shape even the most demanding parts without the risk of overheating or deformation. Cutting accuracy can be as high as ±0.1 mm.

Waterjet technology is widely used in the aerospace, automotive, glass and medical industries, where high precision and the ability to process a variety of materials without damaging them is required.

Waterjet head - the heart of the waterjet machine

The effectiveness of a waterjet machine depends on many factors, and the cutting head plays a key role. It is it that affects the quality and precision of the water jet, which directly translates into the accuracy and aesthetics of the cut parts. In addition to the head, the machine design, pump, pressure, control system and software are also important.

The cutting head is the most important component of a waterjet system, as its design determines the parameters of the cutting water jet. It affects:

• Cutting quality
• Dimensional accuracy of the parts being cut
• Effectiveness of the entire machining process

Modern waterjet systems are equipped with computer-controlled angle-compensated cutting heads that enable dimensional tolerances of ±0.001" (±25 μm). This means extreme precision, which is important in industries such as aerospace, automotive and electronics.

Influence of parameters on cutting quality

In order to achieve the highest cutting quality, it is necessary to adjust the machine's parameters accordingly:

• Cutting speed vs. quality. Cutting too fast can lead to a decrease in edge quality, so it is crucial to properly balance these parameters.
• Cutting angle compensation. Modern heads can correct angular deviations, eliminating the taper effect and ensuring an even cut.
• Pressure-to-cut speed ratio. Higher pressure allows for faster cutting, but involves the use of suitably robust materials and components.
• Water jet diameter vs. cutting speed. A smaller jet diameter provides greater precision, but limits machining speed.
• Distance of the nozzle from the workpiece. A low, controlled and safe distance between the nozzle and the material is key to avoiding energy loss and cutting distortion.

The cutting head is one of the most essential components of a waterjet system, affecting the quality, accuracy and efficiency of the cut. Modern technologies enable computer control, angle compensation and achieve exceptional precision. In order to fully exploit the potential of a waterjet machine, it is necessary to optimally select operating parameters, such as pressure, cutting speed and distance of the nozzle from the workpiece. This makes it possible to achieve the highest quality and precision in the waterjet cutting process.

Types of waterjet cutting

Water jet cutting is a modern processing method that uses the force of high-pressure water to precisely cut through various materials. There are two main types of this technology: pure waterjet cutting and abrasive waterjet cutting. Pure water cutting is primarily used for soft materials such as plywood, plastic, rubber, foam and food. In this process, the kinetic energy of the water jet alone is sufficient to effectively cut through the material, eliminating the need for additional abrasives.

On the other hand, for harder materials such as metals, glass, stone or carbon fiber, abrasive waterjet cutting is used. An abrasive is added to the water to increase the cutting ability by eroding the material. Here, the water jet acts as a carrier that imparts tremendous speed and force to the abrasive, enabling it to effectively cut through even very tough surfaces. This process is often referred to as "abrasive water jet cutting" because it is the abrasive particles that do the actual cutting.

Both methods are widely used in industry and allow precise and safe cutting of various materials without the risk of overheating or deformation. As a result, waterjet cutting technology is valued in many industries, from automotive to aerospace and construction.

The role and importance of the high-pressure pump in the cutting process

The high-pressure pump is one of the most important components in waterjet cutting systems. Its proper selection has a direct impact on the quality and speed of the cutting process, which translates into production efficiency and cost optimization.

Key parameters of the pump:

In order to achieve the required cutting parameters, such as edge quality, machining speed and dimensional precision, it is necessary to pay attention to three main features of a high-pressure pump:

• Power: defined in horsepower (hp) or kilowatts (kW), it affects the pump's performance and its ability to generate adequate pressure.
• Operating pressure: measured in PSI or bar, determines the cutting speed at a given bore diameter and number of cutting heads. In practice, there is an almost direct relationship between pressure and cutting speed: higher pressure results in faster cutting.
• Water output power (flow rate). Depending on the power-to-pressure ratio, it determines the amount of water the pump is able to deliver, expressed in gallons per minute (GPM).

Today's most common pumps on the market are amplifiers, which offer high performance and stable operation. The right selection of a pump for a specific application optimizes the cutting process, minimizing operating costs and ensuring high quality machined edges.

Understanding the relationship between power, pressure and flow rate is key to achieving optimal cutting performance. By choosing a pump with the right parameters, you can not only increase productivity, but also ensure precise and cost-effective waterjet cutting.

Parts maintenance on waterjet machines - what to keep in mind?

To ensure the long and efficient operation of Waterjet machines, regular monitoring and maintenance of wear-prone parts is crucial. This is especially true for all parts that come into contact with high-pressure water and those through which the abrasive flows.

Most important components and their service life:

• Stirring tubes - their service life is 30 to 60 hours, after which they should be replaced.
• Gemstone orifices - they last much longer, more than 500 hours, before needing to be replaced.
• Pump gaskets - their life span is from 500 hours to more than 500 hours before needing to be replaced.
• Pump seals - require replacement every 1,000 hours or so of machine operation.

Regular maintenance of these components avoids costly breakdowns and keeps the machine in optimal operating condition.

4. Waterjet machine investment costs

The cost of investment in a waterjet machine depends on a number of factors that affect the operational expenses of waterjet cutting. Key elements include operating parts, pump power, water consumption, number of cutting heads, abrasive cost, and material type and thickness. Additionally, it is important what kind of edge quality one wants to achieve. Because of these variables, the final cost of operation depends on the specific application of the machine.

5 Summary

Waterjet cutting is an advanced processing method that uses a jet of water at very high pressure, with or without abrasive, to precisely cut a variety of materials. This technology makes it possible to process a wide range of raw materials, such as metals, glass, ceramics, wood, stone, plastics and composites, without heat affecting the structure of the material. This eliminates the risk of overheating, deformation and structural changes. Waterjet is also an environmentally friendly solution, as it does not emit harmful gases and does not produce much waste.

In summary, the advantages of waterjet cutting include:

• No influence of heat - cutting is carried out by a non-thermal method, which eliminates the risk of overheating, deformation and structural changes in the material.
• High precision - the ability to achieve complex shapes and thin edges without the need for additional machining.
• Versatility - suitable for almost all materials, from soft (e.g. rubber, plastic) to very hard (steel, ceramics, glass).
• Cutting large thicknesses - allows processing of materials up to 250 mm thick.
• No mechanical damage - there is no wear and tear on the cutting tool, as cutting is carried out using only water and abrasive.
• Ecological solution - no emission of harmful substances, the possibility of filtration and reuse of water.
• Minimal material waste - thanks to a thin cutting gap and precise placement of elements on the sheet of material (so-called nesting).
• Possibility to cut complex patterns - waterjet allows for 3D cutting, scribing and beveling.
• No need for additional machining - high edge quality eliminates the need for grinding or deburring.
• Process automation - modern CNC waterjet machines provide precise control over the cutting process, increasing productivity and repeatability.
• Process safety - the absence of sparks, smoke and toxic substances makes waterjet cutting safe for the operator and the environment.

This method is widely used in the aerospace, automotive, construction and furniture industries, as well as in the production of precision parts with high quality requirements.