Waterjet Training Guide

Step 1 Waterjet

Videos
https://www.youtube.com/watch?v=g4jX7cim...

Step 2 Familiarizing Yourself with the Waterjet

Familiarize yourself with the terminology specific to the waterjet. They will be used throughout the rest of this guide.
  • Familiarize yourself with the terminology specific to the waterjet. They will be used throughout the rest of this guide.

Step 3 Understand how the Waterjet Nozzle Works

The nozzle essentially shoots extremely high pressure water with abrasive garnet to cut through most materials.
  • The nozzle essentially shoots extremely high pressure water with abrasive garnet to cut through most materials.
  • 30,000 to 60,000 PSI water is ejected through a .008″ ruby or diamond orifice at the speed of sound
  • Venturi effect draws air and garnet into the nozzle
  • It is mixed in the mixing tube and exits as a stream nominally .030″ diameter
  • Abrasive garnet performs most of the work of cutting, having been accelerated by the water stream

Step 4 Safety

Hazard: becoming pinched or entangled in the machine
  • Hazard: becoming pinched or entangled in the machine
  • Hazard: cut by the waterjet stream. Extremely severe – immediately call an ambulance and treat as gunshot wound due to water/air/abrasive injection into the bloodstream
  • Hazard: hearing damage due to operating sound
  • Hazard: cut or pinched by heavy material
  • Hazard: toxic material exposure due to cutting
  • All Hazards are more likely and more severe on larger waterjets

Step 5 Waterjet Uses

  • Plate with holes in it
  • Sheetmetal parts
  • Plastics that can’t be lasercut
  • Art / sculpture
  • Rough cutting prior to machining

Step 6 Allowable Materials

  • Check with each shop you use – allowable materials lists vary
  • Yes: Most metals, including steel, stainless steel, copper, zinc, and aluminum
  • Yes: Plastics and rubbers
  • Yes: Stone, annealed glass, and ceramic
  • Yes: Composites cut well on the ProtoMAX, but may delaminate on larger waterjets
  • No: Wood cuts poorly and makes the water grow bacteria
  • No: Lead, toxic heavy metals, beryllium, or their alloys
  • No: Tempered Glass, it will shatter

Step 7 Training Project

Import the Keychain template from "Manus Training" on the desktop
Save As - name your file
Add Text
  • Import the Keychain template from “Manus Training” on the desktop
  • Save As – name your file
  • Add Text
  • Recommend Maximum 3 characters. Stay with the simpler fonts. Start with a scale of 0.3
  • Adjust using the Size, Move, and Select tools
  • Select the original template geometry
  • Right click “Select” -> connected
  • Set Quality of “3” – Right click Quality – Selected – 3

Step 8 Training Project 2

Add a tab
Autopath
Right click Autopath-> Advanced & Configure to change start and end points, linking strategy
  • Add a tab
  • Autopath
  • Right click Autopath-> Advanced & Configure to change start and end points, linking strategy
  • Post
  • Your mouse pointer will prompt you to select the beginning of the path
  • Verify cutting is on the correct side of the line, and fits your geometry appropriately

Step 9 IMPORTANT: Add tabs

  • This step is REQUIRED for smaller pieces or materials that will float up once cut and RECOMMENDED for all jobs.
  • Press Ctrl-T to switch to inserting tabs. The size of the tabs may be wrong relative to the size of the piece you’re adding the tab to. You can change the dimensions of the tab in the bottom left corner of the screen under “Options”

Step 10 Precision

The waterjet stream is approximately .030" / .75mm in diameter, which determines minimum slot size and inside radius size
  • The waterjet stream is approximately .030″ / .75mm in diameter, which determines minimum slot size and inside radius size
  • Accuracy and repeatability
  • Protomax .005″ specified, may perform better
  • Large waterjets .0005″
  • If you care about precision, you must perform a test cut, on your material, each time, to account for nozzle wear
  • Kerf width can vary from .015″ to .055″
  • Taper varies from 1 to 5 degrees, depending on material, quality, and nozzle wear

Step 11 Choosing the right quality

Right click on the "Quality" button on the bottom toolbar and select "All"
  • Right click on the “Quality” button on the bottom toolbar and select “All”
  • A new box should pop up with choices from 1 to 5. For most situations, quality 3 is sufficient, so select quality 3 as highlighted in the image.
  • Note that the higher the quality, the slower the machine will cut and thus the more time and garnet the job will take (i.e. it will be more expensive).

Step 12 Pricing

  • Make sure to note active cut time and check in with a mentor to pay on Mobius
  • Current pricing $0.25 per minute.
  • Waterjets on campus vary in cutting productivity. Ours is the slowest.

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