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Waterjet Cutting Chennai

Why Waterjet Cutting?

Abrasive waterjet cutting is essentially a cold cutting process. The work piece are not heat-stressed or no structural changes are induced that can adversely affect metallurgic properties in materials being cut.

Why Waterjet Cutting at Alind ?

  • Capable to cut simple to complex 2D shapes in virtually all metallic and non-metallic materials
  • Fast and economical profile cutting, either for single or production runs
  • We can cut thicknesses up to 150 mm on any metal and up to 250mm in non metals
  • Tolerance: +/-0.1 to 0.3 mm depending on thickness and length of part
  • Unlike flame/plasma/laser cutting process there is no heat affected zones (HAZ)
  • No warping during cutting process, hence long length to width ratio and frail parts can be cut
  • No fatigue zones, no thermal distortion or degradation in physical properties of materials
  • No discoloration and offers edge finish similar to sand blast finish
  • No heavy burrs are produced. Often, parts can be used directly without de-burring
  • Unlike milling, there is no vibration on the parts to be machined
  • No chatter, even brittle materials and heat treated, hardened steel can be cut
  • No long lead time tooling and no need for costly fixtures. Very minimal set-up cost
  • Quick parts –From Concept to part production just a CAD drawing will do
  • Scrap produced has a higher value and fully re-usable as there is no dross or slag
  • Tight Nested layouts of shapes, with minimal kerf width of less than 2mm, offer great productivity
  • ALIND's water jet cutting envelop is 3mx1.5m and easily accommodates full size standard plates

When Comparing with EDM

  • EDM is extremely accurate, but very slow. It also requires an electronically conducive material
  • Abrasive jets are capable cutting wider variety of materials including Non conducting materials
  • Abrasive waterjets make their own pierce holes. Much faster than Wire EDM
  • Abrasive waterjets are capable of ignoring material aberrations that would cause wire EDM to lose flushing
  • EDM cannot take full advantage of closely nesting your part in full sheets.
  • Abrasive waterjets require less setup and can cut bigger parts
  • When the accuracy is open tolerance or in the range 0.1 to 0.3mm,waterjet cutting is the best

When comparing with Lasers

  • Abrasive waterjets can machine many materials that lasers cannot. (Reflective materials in particular, such as Aluminum ,Brass and Copper).
  • Uniformity of material is not very important to an Abrasivejet.
  • Abrasive waterjets do not heat your part. Thus there is no thermal distortion or hardening of the material.
  • Our abrasive jet machine can obtain about the same or higher tolerances than lasers (especially as thickness increases).

When comparing with Plasma and Flame cutting

  • No work-hardening of edges, no HAZ and no micro cracks
  • Edges are left perfectly clean with much nicer edge finish
  • Abrasive waterjets are precise, needs no for further machining or labour-intensive finishing.
  • Profiles can be much more closely nested, hence more parts per sheet
  • With higher accuracy further machining is less and quick in other tools
  • Abrasive waterjets can cut virtually any material
  • Abrasive waterjets can cut higher thickness
  • Plasma/ Flame cutting is typically cheaper
  • Flame cutting a part needs time consuming finishing operation, waterjet cutting saves your other tools from having to do so much work!

When comparing with miling

  • There is no extensive cutting tools required.
  • No long Setup time and no fixture Cost.
  • Abrasive waterjets cut a part with one pass.
  • Machine virtually any material, including:
    • brittle materials
    • pre hardened materials
  • otherwise difficult materials such as Titanium, Hastalloy, Inconel, SS 304, hardened tool steel....
  • Milling cannot take full advantage of closely nesting your part in full sheets.
  • The scrap is usually more valuable in solid form than chip form.Waterjet cutting do not reduce all the metal to chip form.
  • Waterjet cutting can be used for complimenting or replacing milling operations. They are used for roughing out parts prior to milling to take advantage of nested cutting layout.

When comparing with Punch Press

  • Lower cost per piece for short runs and fast turn-around from concept to production
  • Abrasive jets offer more nesting possibilities ,hence more parts per sheet
  • Place holes closer to the materials edge
  • Thick materials are fine,Brittle materials are no problem and Hard materials are easy

Waterjet Cutting Methodology

Most abrasive waterjet cutting theories explain abrasive waterjet cutting as a form of accelerated micro erosion. High pressure water at 3800 bar is passed thru a tiny orifice at a speed of approx.900 m/s – nearly three

times the speed of sound. The result is a coherent very thin extremely high velocity waterjet with a diameter of approx. 0.08 to 0.50 mm. Natural garnet sand particles are made to be sucked into the stream of the coherent waterjet and directed to hit the work piece on the cutting line with the very high velocity. There by hardest of metals and non metals can be cut or machined by micro erosion. Automating the process with programmable systems in conjunction with the CNC control provides precision and high flexibility with a wide variety of part profiles.

Thus, Abrasive jet cutting systems are considered as an efficient tool to cut work pieces which are previously considered "unmachineable" by conventional cutting methods.