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KMT Waterjet Cutting Tips, Tricks & FAQ's

Whether you have a new or old waterjet system, or are just interested in learning more about waterjet cutting technology, KMT Engineers, Sales Staff, Technical & Customer Service folks are eager to share their waterjet cutting advice, tips, tricks and hints.  We have included their contact information, so please feel free to contact them with your comments or questions.  We are here to help!

Have a better way of waterjet cutting, tips, advice, tricks or hints?  Contact Us or send an e-mail describing your technique or advice. If it's new to us and we print it, we'll send you a Big Dogs Cut With Water T-shirt. Be sure to tell us your size (S, M, L, XL, XXL). 

Whether you're a waterjet cutting pro, or new to the waterjet cutting industry, you'll want to check out our waterjet tips and tricks listed below.

KMT Product Animations:

 KMT Waterjet Cutting System Overview (9mb Animation)

 KMT Waterjet Pump Intensifier Flow (1.8mb Animation)

 Correct Waterjet Cutting Speed Example (3.5mb Animation)

 Incorrect Waterjet Cutting Speed (Too Fast) Example (5.6mb Animation)

KMT Waterjet general Information:

 KMT Introduction to Waterjet Cutting - Overview (PDF 285kb)

 KMT Orifice-Cutting Speed Chart (291kb)

 KMT Waterjet Worldwide Offices - Contact Information (83 kb)

Chuck’s KMT Tips and Tricks

Chuck Schmidt, NE Area Manager USA, 417-291-0280 or e-mail: chuck.schmidt@kmtwaterjet.com 

1.) Want to know how to extend the life of your HP Seals? KMT can help!
The old adage “Garbage In, Garbage Out”, also applies to seal life...

• Cleanliness IS next to godliness.
1. Use latex gloves when reassembling the seals and
2. Thoroughly clean the plunger and cylinder wall before reassembling
3. Use only FML2 Lube on the HP Seals

• Water quality is the single most overlooked issue
1. Do you have hard water?
2. Do you have solids in your water?
3. Get Your Water Tested, Get More Seal Life!!

• Can You Change Your HP Seals In 15 Minutes??
1. KMT Can, Ask Me How

2.) Save Your Diamonds and Sapphires From UFOs!!!
Are Untimely Failed Orifices sightings occurring in your facility?

• Diamonds last longer than sapphires, but Untimely Failed Orifices can be prevented.  After a repair or installation of HP tubing, simply remove the orifice and cycle the intensifier on and off.  This will flush the HP line and blow out any debris. Reinstall the orifice and you are back in business.

Abrasive Feed Check

Pat Angiolillo, E Canada & SE USA Area Manager, 417-291-6117, or e-mail: pat.angiolillo@kmtwaterjet.com

Check the feed rate of your abrasive feeder, inconsistencies in the abrasive supply rate may lead to plugging of the cutting head resulting in reduced cutting speed, increased downtime & operating (abrasive) costs and ultimately resulting in poor cut quality. Orifice monitored systems are inconsistent as they rely on the “ideal” conditions of abrasive being properly fed through the hopper opening. 

The vacuum generated by the jet plays a significant role in this process as well. During start and stop sequences, the vacuum varies greatly. This inconsistency creates either low or high vacuum condition. The abrasive supply rate entering the system is directly proportional to the amount of vacuum generated. For instance, a low vacuum condition causes a low volumetric abrasive feed rate to the cutting head, resulting in poor cut quality and increased processing (cutting) time. The opposite is also true. A high vacuum increases the abrasive supply rate into the cutting head causing plugging, premature wear of the mixing chamber and abrasive nozzle, subsequently resulting in poor cut quality. While it is an investment, I recommend a system that positively controls the abrasive feed rate.

Skip Reynolds, Food and Emerging Markets Manager, 417-291-2369 or e-mail: skip.reynolds@kmtwaterjet.com

Outside of standard operation cost one of the largest expenses to a Waterjet is the abrasive. A daily check of the abrasive feed rate can save time and money. If feed rate gradually slows down without your knowledge then automatically you slow down to retain quality. A daily check will decrease cost and increase productivity.

Try rotating the focusing tube by 90 degrees at the end of every shift. A constant rotation schedule will help reduce irregular wear of the focusing tube, thereby extending its life by many hours. This simple, ten second habit at the end of the day can end up saving you hundreds of dollars per year or more.

KMT Service Technicians "Lucky 13" Tips

Jeff Frampton, 800-826-9274 or e-mail:  jeff.frampton@kmtwaterjet.com

Charlie Mitchell, 800-826-9274 or e-mail: charlie.mitchell@kmtwaterjet.com

Darrell Smith, 800-826-9274 or e-mail: darrell.smith@kmtwaterjet.com

1. When installing an orifice into an Autoline nozzle, make sure the orifice seals to the nozzle tube before operation.
2. When rebuilding a valve assembly make sure to keep the position tool in place until the stem has been installed all of the way into the seal.
3. Use goop any time the intersection involves stainless steel on both parts and the possibility of one or both parts moving during the install.
4. When calling technical service for advice be prepared to identify the piece of equipment being worked on. It will decrease your down time.
5. Twice a shift, check the temperature of the sealing heads comparing it to the other end. Repairing when heat is felt will cut operation costs.
6. Install a high pressure gauge if possible. A high pressure gauge is the most helpful troubleshoot tool we can use. A lot of systems do not come with one; instead they rely on the hydraulic pressure gauge and they are not always correct.
7. Only cut with the PSI you need. Many pumps will cut at 87,000 PSI and 60,000 PSI but just because the pump will do it, does not mean you have to use it. It is great to have the higher pressure if you need it, but some jobs are different, particularly in job shops. There are many benefits to running at lower pressure. The biggest being your consumables will last longer and there is less stress on the pump. Also, on some materials you can cut just as fast with 45ksi as you can at 60ksi.
8. Make sure you do preventative maintenance. Check the hours on the seal and change them when it is time to. It is better to change the seals at your convenience than in the middle of the job when they decide to go out.
9. Here’s a quick fix for unclogging a focusing tube. Turn your focusing tube over and turn the jet on. It should dislodge anything that is in the tube.
10. Make sure your stand off is no more than 1/16 in. The farther away you are from the surface of what you are cutting the less quality you will get.
11. Consistently check the quality of your cut. If the kerf width is widening then it may be time to change out your focusing tube.
12. If the material being cut is submersible, then it will significantly lower the audible level of the cutting.
13. Remember when buying a Waterjet system make sure to get one that meets your design needs. KMT manufactures pumps that will run 20-30 cutting heads at 35ksi to a pump that will run multiple heads at 90ksi. It also does not hurt to get a pump that is more than you need. Most people buy their Waterjet for one specific reason, then later they realize what else they could be doing with it.

Bryon Machado, Area Manager S Central USA, 417-291-3281 or e-mail: bryon.machado@kmtwaterjet.com

Cut more parts in less time! To increase productivity per part try reducing the number of sharp angles.  This allows you to maintain linear speed while using a Dynapierce (where the head moves in an small oval).

The clear way to cut glass! When cutting glass you should cut on waterjet bricks to help prevent cracking. Also try putting a layer of water on the material to reduce the risk of the abrasive scratching the finished product.

Solid advice for stone integrators!  To maximize the overhang distance on countertops try underlaying a .25" piece of steel underneath the stone. This will let you eliminate the need for supports and have more leg room underneath the bar top.

Operating Tips

Waterjet in Summer – Humidity has a big effect on abrasive flow. If abrasive clogs are slowing you down, try a warming band on your abrasive hopper. It will warm up the abrasive and remove moisture.

Don’t Lose that Orifice – Put a tray under the Autoline cutting head when disassembling! Or, try the new IDE head with built-in orifice.

Seems obvious, but water treatment is key to reducing maintenance.  High pressure waterjet lines are like arteries – if material is allowed to accumulate inside, eventually, problems will show up in far away areas.  By changing pump filter(s) regularly, you will notice better all-around performance.  If the system has been neglected, add an inline high pressure filter to your high pressure tubing line – it just might reduce your purchases of orifices, valve stems and seals!

Diamond orifices can be used longer when cleaned regularly with an ultrasonic cleaner (even a basic jewelry-type cleaner will work).  Most diamond orifices stop because they get clogged, not because they breakdown!

Operation Pressure Tips

From Antonio Diaz, Area Manager South & Central America, +52 1 449 415 9645 or e-mail: antonio.diaz@kmtwaterjet.com

"Ajustar la presión de operación del intensificador en aplicaciones de corte con agua pura."

El disminuir la presión de operación del intensificador, en la medida que lo permitan los diferentes materiales, manteniendo un acabado de corte constante y una velocidad aceptable para nuestros clientes, nos permite en gran medida el prolongar la vida útil de los componentes de desgaste en nuestra bomba, reduciendo así los costos de operación de la misma.

Three Important Waterjet Tips to Know!

1.  After replacing or cleaning Orifices with angled bodies (Autoline I & II, etc) several times, it pays to inspect the mating surface of the Nozzle Tube where it contacts the top of the Orifice body. Over time, this surface can become indented with a "witness mark" from the Orifice rim. If this mark is prevalent, more pressure is required to complete the seal between the Nozzle Tube and the Orifice. Over-tightening to make this seal can damage the Orifice prematurely.

2.  When installing a Focusing Tube into your cutting head, listen for the metal-to-metal "clink" between the top of the Focusing Tube and the Bottom of the nozzle's Wear Insert. If it doesn't "clink", there are abrasive particles between the parts, thereby creating a small void. This space can decrease the efficiency of your cutting head.

3.  For water-only applications with minimal on/off cycles, consider using KMT's patented SuperTube assembly. This assembly minimizes turbulence above the Orifice, which produces a longer, more coherent cutting stream. This improved stream can increase cutting power and minimize material wetting.
 

Alguns cuidados simples porém eficazes que resultam em economia e evitam prejuizos:

- Faça a aferição diáriamente da quantidade de abrasivo que você gasta no corte de suas peças em comparação ao estimado em seus custos.
Lembre-se, aproximadamente 70% do custo de corte é o abrasivo!

- Antes de trocar um orifício, remova todo o abrasivo acumulado na parte externa da cabeça de corte com o auxilio de uma mangueira com água. Somente após isto, troque o orificio. Caso contrário, você corre o risco de deixar particulas de abrasivo no tubo principal (anterior à cabeça de corte) o qual pode gerar vazamento através da deformação do montante do orificio.

- Os orificios de Safira e Rubi, os quais possuem uma vida de no máximo 1/10 em comparação aos feitos de Dimamantes naturais, não são perfeitamente alinhados, fato este que ocasiona o desgaste irregular interno do tubo de mistura, tornando o jato impreciso precocemente. A melhot maneira de minimizar este efeito é girar o tubo de mistura em 90 graus em relação ao corpo da cabeça de corte a cada uma hora de uso. A KMT produz orificios de Diamante 100% naturais !

Bom trabalho e a sua disposição para outras dicas, suporte, peças e bombas!