Waterjet Applications ExposedTim Fabian & Marjorie MillayFlow International Corporation

Agenda

Brief comparison of waterjet to other processes

Traditional applications

Why choose waterjet for a specific job?

Emerging applications

Applications you never thought possible

Comparing Waterjets to Other Processes

Waterjet

Plasma

Laser

EDM

Plasma

Large Kerf (~ 0.060”) Large Heat Affected Zone (~0.125”)

Laser

Small Kerf (~0.010”) Small Heat Affected Zone (~0.025”)

Waterjet

Moderate Kerf (~ 0.040”) No Heat Affected Zone

Comparative CuttingMaterial Utilization

The Heat Affected Zone (HAZ) develops when metal is melted by the cutting process.

The metal microstructure changes and develops micro-cracks and hardening. Slag formation and thermal deformation can develop.

Structural components (such as those used in aerospace applications) subject to large loads could experience catastrophic failure under a load stress.

Hardening and slag formation cause excessive machining tool wear on secondary operations.

Waterjet Plasma Laser EDM

ProcessErosion process - high speed

liquid sandpaper.

Burning/melting process using high

temperature ionized gas arc.

Melting process using concentrated laser light

beam.

Erosion process using electrical discharge.

Capital Investment

$60k to over $300k. $60k to over $300k. $400k to over $1M. $100k to over $400k

Materials Any material.Primarily steel,

stainless steel and aluminum.

Primarily steel, stainless and

aluminum.

Can also cut a variety of other materials.

Conductive Materials Only

Thickness

Up to 24 inches, virtually any material.

Z constraint is only limit to thickness

Up to 2-3 inches, depending on material

Generally 1 inch or less, depending on

materials.

Generally 12 inch or less.

Part Accuracy

Up to .001” Up to .010” Up to .001” Up to .0001”

PROCESSCOMPARISON

Summary of Waterjet Technology

Pressurized water up to 94,000psi

Available in pure waterjet or abrasive jet

A cold erosion process

The most versatile machine tool in the world

Capable of part tolerances up to .001”

Waterjet IS….

Waterjet IS NOT….A tool that uses heat in the cutting process

Limited by material properties

Expensive to purchase

“Traditional” Waterjet Applications

RubberPlasticLeatherWood

SOFTERMATERIALS

HARDERMATERIALS

Stainless SteelHardened Steel

Mild SteelAlloys

TitaniumAluminum

StoneGlass

CompositesCeramic

Why Use A Waterjet?

No material limitations

When Heat Affected Zone(HAZ) is a problem

Reduce secondary processing

Thick or thin materials

Why Use A Waterjet?

Reflective materials

Net or near net shapes

Quick piercing in small areas

Better material utilization

Unique Waterjet Opportunities

Flow Flow WaterjetsWaterjets can cut can cut any solid material any solid material

including stone, tile, including stone, tile, glass, metal, foam, glass, metal, foam,

rubber, plastic, rubber, plastic, and foodand food

Pure Water OpportunitiesAny soft material

Foam

Rubber

Gasket material

Belts

Replace die cutters,shears, blades

Often multiple heads

Industries – custom foam packaging, gaskets

FoodUSDA approved

No blades needed!

Chicken/Fish

Pizza

Food

Veggies

Baby Carrots

Fig Newton's

Cake

And much, much more!

Ceramics, Tile & Stone

Pierces throughbrittle materials

Stone inlays

Countertop industry

Able to cut through tough ceramic composites such as zirconia or sintered ceramics

GlassBehaves similar toceramics & stone

Stained glass

Bullet proof glass

Optical glass

Flat glass forshowers ormirrors

Laminates & CompositesNo mechanical stresses, no delamination, no fiber pull out (whiskers), no microcracks

Doesn’t dull like routers, saws or lathes

No HAZ or airborne dust

Faster cutting of composites than other methods

Leading edge composites MHI Proprietary

PrototypingCut out the shape in anymaterial

Quickly and easily try out different designs

Materials testing

“Art to Part” in 1 minute

Diemaking

Milling

Can be used where traditional milling is problematic

Difficult to machine materials such as ceramic titanium, Inconel®

Thin walls subject to deflection

Milling

Extremely tight inside corners

1300 ft/minute equals .001” depth of cut

Depth controllable to approximately .002”

125 rms finish

Turning

Best suited for materials difficult to machine

Abrasive mesh size has significant impact on speed

Rotation direction effects surface finish

Rotary Axis/Indexing

First done by Flow in 1997

Has lost ground with evolution of true 5-axis due to limitations

Best suited to round stock material

Hole DrillingWhen many small holes are needed

Often used in Aerospace applications

Most common with ceramics and advanced alloys

Up to 3 holes per second using new technology

“Green” OpportunitiesAccording to EnvironmentLeader.com, Obama’sSpending on Green initiatives in stimulus plan is estimated to be $50 billion dollars

A vast majority of that spending is to take place in 2010

“Green” Opportunities

Solar Cells

Wind Turbine Blades

Lightweight materials

Real Life Examples

Gasket Suppliers Diversify

“Flat Stock” Waterjet Job Shop goes 3D

Gasket Suppliers

Similar operationsVast inventory

Lots of choices

Custom options

Counter sales

Gasket Suppliers

Similar operations

Three different directionsSupplement die cutter

Gasket Suppliers

Similar operations

Three different directionsSupplement die cutter

Productivity toolPure water

Two quad head systems

Up to 10 sheets

80 parts at a time

Gasket Suppliers

Similar operations

Three different directionsSupplement die cutter

Productivity tool

Expand businessAbrasive option

Broadens materials

Broadens markets

Dynamic XD Job Shop

EXISTING WATERJET USER “EMS” WOULD LIKE:To expand their capabilities

Replace 5-axis plasma and other equipment

Multi-axis part accuracy of +/-.001”

To eliminate man hours needed for secondary operations

True 3D 5-axis solution, not just a bevel cutter

Customer Part - Before

Used multi-axis plasma

Multiple part set takes 120 man hours

Low tolerance required large gaps to be left for welds

Elaborate fixturing needed for welding

Customer Part - After

Uses Dynamic XD

50% less time for finished part

Fits tight together

No fixturing required for welding operation

Much more attractive part to end user

Proven Results

Precise 3D/Multi-axis

Dynamic XD now allows 3D “art to part” in a minute

Ability to import solid models

Dynamic Taper Compensation in 3D

3D Modeling and speed compensation

“The Dynamic XD is awesome, it is saving me time and money, and the part quality is excellent. I’m realizing a huge labor savings – for example, to produce one part in the past took 2 guys 1 ½ weeks to complete. Using Dynamic XD, that same part takes one guy 2 days to complete which is a huge labor savings and translates to tremendous cost savings. Plus, the part requires no secondary finishing.”

-Brad Davidson, Owner

ConclusionWaterjet technology compares favorably to other processes

Waterjets can handle virtually any material-making diversity it’s greatest asset

The applications for waterjet technology are limitless and ever-expanding

Users everyday are discovering how the latest in waterjet technology helps them expand their business

Questions?Thank you for you attending.

For a complimentary needs analysis or a product demonstration contact us at info@flowcorp.com or visit us at www.flowcorp.com.