Tile cutting with water under pressure

Table of Contents:

Equipment

The water jet cutting machine consists of:

  • high pressure pump;
  • tool head;
  • desktop;
  • belt-driven motion systems or CNC controls;
  • working bath (stainless steel);
  • tanks for supplied water;
  • tank for abrasive material;
  • a compressor for supplying abrasive material;
  • a sensor designed to control the abrasive;
  • mixing chamber;
  • a remote control with a flywheel designed to simplify the control procedure;
  • a device designed to remove the remains of the processed material;
  • device for feeding workpieces.

tile, cutting, water, pressure

Technology

The cutting tool for waterjet cutting is a jet of water together with an abrasive material. A jet of water is supplied at high speed under high pressure. from 2000 to 5000 atmospheres. In some devices, the pressure can reach 6000 atmospheres.

Water flows through a nozzle with a thickness of 0.1 mm. In this case, the speed of the water increases, and can reach values ​​of 1200 m / s and even higher. The water flow is focused, it can cut almost all metals. Water consumption is up to 4 l / min.

After the nozzle, water enters the mixer. Particles of abrasive material are also fed here. At this point, the mixing of water and abrasive material takes place. The abrasive is fed tangentially. A mixture of water and abrasive gets on the workpiece. Under the influence of a focused high-speed flow, particles of the processed material are detached from the cut.

The principle of operation of the installation for waterjet cutting

During the cutting process, it is important to adhere to certain parameters and follow the rules for using the machine. It is important here what water pressure is used, what flow rate, jet speed, the amount of supplied abrasive material.

On the diagram, the numbers show:

  • 1. water supply;
  • 2. nozzle;
  • 3. abrasive material;
  • 4. mixing device;
  • 5. casing;
  • 6. a stream of water and abrasive;
  • 7. processed material.

The process of waterjet cutting of metal includes 4 stages:

  • The workpiece is placed in a water bath and fixed. On a non-automated device, you need to do it yourself, on a CNC machine. using the program.
  • A tool head is placed in the bath, into which water and abrasive are supplied. This sets the required operating parameters (water pressure, flow rate, etc.).
  • The tool head is guided to the workpiece material.
  • A jet of water and abrasive cuts the workpiece.
  • After cutting, the abrasive material is filtered and dried.

waterjet cuts ceramic tile

The listed steps are constantly repeated during the operation of the device. The metal is cut by the impact of the abrasive particles. Water, in this case, acts as a carrier of cutting particles (that is, abrasive). Used as an abrasive:

  • quartz sand;
  • silicon carbide;
  • garnet abrasive;
  • electrocorundum;
  • olivine.

This type of cutting is actively used for processing alloy steel workpieces. This is due to the fact that the jet of water and abrasive does not violate the composition of such steel. In addition to metals, glass, stone (natural and artificial), concrete and reinforced concrete can be processed. But, each material has its own thickness limits:

  • Non-ferrous metals, alloys and stainless steel. maximum 150 mm.
  • Composite materials, CFRPs. maximum 200 mm.
  • Natural and artificial stone. maximum 300 mm.

cutting metal with water.

What is the principle of operation and technology of cutting metal with water?

Let’s look at the technology of cutting metal with water and its principle of operation. During various works (both in industry and in everyday life), it is often necessary to cut metal structures. For this purpose, mechanical, laser, oxygen, plasma cutting is used. That is, for cutting metals, mainly mechanical action or high temperature is used.

Each of these methods has its own advantages and disadvantages. For example, during mechanical cutting, metal deformation occurs, and during gas-oxygen or plasma cutting. to its oxidation.

  • Advantages and Disadvantages of Waterjet Cutting
  • Equipment
  • Technology
  • The principle of operation of the installation for waterjet cutting
  • Safety engineering

Advantages and Disadvantages of Waterjet Cutting

In modern industry, a new type of metal cutting with the help of water is actively used. This is called water abrasive or waterjet cutting. This method was first used in the aircraft industry.

This technology does not have the disadvantages that are inherent in cutting metal by mechanical action or high temperature. For the first time this technology was applied in the 70s of the last century. In industry, it began to be actively used at the end of the 20th century.

Cutting metal through exposure to water and abrasive has a number of advantages.

  • The workpiece does not heat up or deform.
  • High-quality cut, so there is no need for post-processing of the product.
  • Metal losses are minimal.
  • Parts can be processed in any size and in any mode. manual or automatic (without human intervention).

Using water-abrasive cutting, you can get parts of various shapes. you just need to set certain parameters using numerical control. This factor makes it possible to actively apply this method to obtain various items intended for decorating interiors, buildings, etc.

There are also disadvantages to water-abrasive cutting. First, there can be negative consequences for metals that are prone to corrosion. And, secondly, this type of cutting requires large financial costs. The entire mechanism must be constantly inspected. Equipment often fails and requires repair or replacement.

Safety engineering

The waterjet cutting process is not particularly hazardous. The distance from the tube from which the jet comes out to the treated surface is only 2.5 mm. This eliminates the impact of the jet on the hand. When the water pressure exceeds the permissible value, the relief valve opens, which reduces the pressure to the working one. Nevertheless, when working on machines, certain safety measures must be observed.

  • Never expose your body to the jet. Such a jet is able to cut metal 150 mm thick, let alone a hand. Keep your hands as far away from the cutting area as possible while working. Before turning on the machine, make sure there are no foreign objects in the cutting path.
  • Protect your eyes and hearing. Be sure to use safety glasses and earplugs (or earplugs).
  • Don’t put your hands on your desk.

Leaders in the production of waterjet cutting machines are American companies Jet Edge, Flow, OMAX, Italian WaterJet Corp Inc. and Caretta Technology, Dutch Resato, Czech PTV, Swedish Waterjet Sweden, Finnish ALICO, Swiss Bystronic.

Waterjet cutting

Waterjet cutting is often called waterjet cutting, waterjet cutting, or simply waterjet cutting. Such names for this type of work are due to the modern technology of processing durable material using a water jet directed at it under high pressure and the use of abrasive materials. Water is supplied under a pressure of at least 4130 atmospheres by a high-pressure pump to the self-infusing machine head. This cutting head is controlled by a numerical software system that provides increased precision and cut quality. Water passing through a rather complex system of channels mixes with abrasive sand. After that, a mixture of water and sand at a speed of 1200 m / s is thrown through a thin (0.8 mm) focusing tube with a jet that is capable of cutting a wide variety of shapes from almost any material. This water-jet cutting technology allows you to create the most exquisite and exclusive mosaic panels and rosettes from marble, porcelain stoneware and other materials of high strength.

Waterjet cutting of porcelain stoneware, artificial and natural stone is not such a simple technological process. Porcelain stoneware, natural or artificial stone is usually cut with a milling cutter (disk) on a straight cutting machine when it needs to be cut in a straight line, or using waterjet cutting when it becomes necessary to cut along curved, curved lines. When the material is cut with a cutter, it is not uncommon to get small jagged edges that need additional processing. It is impossible to cut the stone perfectly with a milling cutter, since small micro-chips remain on its edge. When water-jet cutting is used for stone processing, the result is completely different. After using water cutting, an ideal edge is formed, and the edges of the products do not require any additional processing at all, which can be called ideal. Parts or products made during waterjet cutting can be of almost any shape. Such waterjet cutting is considered a kind of artistic stone cutting, thanks to which the most diverse and complex ones are brought to life. Thanks to the technology of waterjet cutting, ventilation grilles, brass decors are often made according to individual designs.

Waterjet stone cutting has long been a replacement for traditional mechanical cutting. It also competes with such complex modern types of cutting as plasma, oxygen, laser and electric spark cutting. Water-cutting is used when it is necessary to process materials that cannot withstand high temperatures. In such cases, this water-jet cutting of the stone is the only one possible. When cutting with water, direct pressure from a water jet is applied to the surface of the material. All mechanical influence on the stone occurs only at the microscopic level. That is why, despite the fact that the water jet has a high kinetic energy, no deformation of the processed material occurs. High-precision water cutting is carried out without bending the edge of porcelain stoneware, marble or stone.

Advantages and disadvantages

Let’s dwell on the positive aspects of waterjet processing before other methods of cutting materials.

  • Cutting is carried out at low temperatures, which does not lead to an increase in the temperature in the workpiece, which is decisive when working with materials that are particularly sensitive to heat.
  • The process ensures high quality of the cut surface.
  • Cutting tool does not need regrinding.
  • Product shock is minimized.
  • No reaction from the material to the tool.
  • Cutting speed. high.
  • The process is fully automated.

The negative aspects of this waterjet cutting technology include: a complex design of equipment that creates a high fluid pressure, the complexity of manufacturing, the fragility of the nozzle.

Cutting materials:

This method of cutting materials is a very powerful tool and allows you to use waterjet cutting for a wide range of materials to be cut:

  • Ceramic tile
  • Porcelain stoneware
  • Marble
  • Granite
  • Metal. steel, stainless steel, brass, titanium
  • Plastic
  • Rubber
  • Glass
  • Plexiglass
  • Mirror
  • Hard and magnetic alloys
  • Composite materials such as carbon

Some materials may not be included in this list. For clarification on other types of materials, please contact us through the Contacts section. production.

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Examples of using

Design
Shape cutting, using a high-speed flow of water particles, allows you to cut the material exactly along a given line, without unnecessary loss of the original material. The materials obtained after cutting are used for the manufacture of volumetric letters, plates and various image signs, a company logo made of ceramics or marble, marble masonry, mosaic flooring or walls, and room decoration. In addition, waterjet cutting is widely used by designers when creating image and individual projects.

Industry
Waterjet cutting machines easily cope not only with any steels, titanium and its alloys, but also with composite materials such as carbon. Therefore, this type of processing was in demand not only in construction and design, but also in industry. The highest quality and speed, with a relatively low cost of the process, have led to the fact that the machines are used in the aviation, metallurgical, electronic, food, automotive and other industries.

Construction
However, waterjet cutting is most widely used in modern construction. The ever-increasing requirements for the architecture of buildings, private houses and apartments, lead to an increase in demand for stylish, exclusive, and sometimes unusual architecture and design projects. Finding ready-made shapes and sizes from manufacturers of building materials, sometimes, do not lead to anything. In this case, the method of water-jet treatment of materials. it is the key to solving many technological problems. It frees up imagination and empowers design artists to a great extent.

Floor or wall mosaics, ceramic tiles, cutting of marble and porcelain stoneware, friezes and decors, company image logos from tiles, generic signs and symbols, elements of oriental architecture, borders, decorations made of stone and metal, glass cutting, decorative elements of furniture and interior, outdoor elements of architecture. here is an incomplete list of the possibilities of waterjet processing of materials.

On the pages of our site you will also find a catalog of products, completed projects made of various materials.

The advantages of this type of cutting

Waterjet cutting. this is an alternative not only to mechanical, but also to laser, plasma cutting, and if it is necessary to process materials that do not tolerate temperature exposure, it is the only possible one.

  • Waterjet precision and quality. The material processed with a high level of quality in most cases does not require further machining of parts, such as grinding, polishing.
  • No thermal effect on the material. This, in turn, eliminates the slightest possibility of deformation of the part, its melting or burning. The heat generated during waterjet cutting is immediately carried away by the water.
  • The consumption of the processed material is reduced. Cutting width from 0.5mm.
  • Waterjet cutting allows you to cut any contours inside and outside parts, including bevel cuts, corners and holes.
  • Wide range of cut materials.

Waterjet cutting

Using modern equipment and the latest technology, Paloma Studio offers a high quality waterjet cutting service for various materials. This service is based on the technology of cutting materials with a water jet supplied under strong pressure, and therefore, the terms “water cutter”, “water cutter”, “water cutter” are often used. This method is used not only for cutting hard materials, but also for very fragile, crumbling materials, for example, water-cutting ceramic tiles.

A little about the equipment

Hydraulic cutting equipment has varying degrees of versatility and automation. Currently, there are entire robotic complexes. The complex for water-jet cutting includes a fairly significant number of a wide variety of mechanisms. This is a program control station, a high-pressure pump, a cutting head, an XY table, a mechanism that provides an abrasive feed. The complex is often supplemented by other devices. A special structure of the nozzle, which is made of artificial stones, participates in the formation of a supersonic jet of liquid as a cutting tool. The most widespread are sapphire, corundum, and diamond. Working time is about 100-500 hours.

A system of fixed and movable pipes conveys water from the high-pressure pump to the cutting head.

The abrasive can be supplied either by a vacuum system that works on the principle of a spray gun, or a system that works under pressure.

Technology

Cutting technology consists in cutting materials along a given line or contour. over, this contour or line can be of any arbitrary shape. The high-pressure water jet has such a speed that it turns into a heavy-duty cutting element and allows you to work with a variety of materials and use this method in various areas of construction and industry. The precision of the cutting tool is so high that it provides, if necessary, a seamless connection of mating parts and mechanisms. However, it must be borne in mind that there are various processing options: rough, good and excellent. The processing speed, and hence the cost, directly depends on the choice of cutting quality.

Specificity of hydrojet cutting of porcelain stoneware: advantages and disadvantages

There are several technologies for cutting porcelain stoneware. Each of them is convenient for a certain direction and scope of work. For small objects, for example, a bathroom cubicle, a manual tile cutter or a grinder is suitable, and for large halls and retail premises you cannot do without an electric tile cutter. But such a tool can only make straight cuts, but for artistic cutting or creating ornaments, waterjet cutting of porcelain stoneware is used. This is one of the best methods for cutting hard materials. The technology allows you to cut any shapes, drawings, and create a false mosaic.

The principle of the machine

The machine for cutting porcelain stoneware has a rather complex mechanism. A high-pressure pump feeds water and abrasive through special channels into the mixing chamber of the cutter, and from it the ready-made mixture comes out of the carbide nozzle. The jet diameter can vary, depending on the purpose and setting of the machine program, and range from 0.2 to 0.4 mm. The caliber of the nozzle itself has dimensions of 0.5-1.3 mm.

Waterjet cutting is capable of cutting:

  • Limestone.
  • Reinforced concrete.
  • Glass.
  • Composite materials.
  • Hardware.
  • Ceramic tiles.
  • Natural stone.
  • Porcelain stoneware.
  • Marble.

The high-pressure water jet cuts the porcelain stoneware tiles without creating a jagged edge. Due to the design features, the water jet machine is able to cut porcelain stoneware at an angle of 45 ° or more.

Unlike a mechanical and electric tile cutter, waterjet cutting of stone is the highest quality work in cutting the finishing material.

Machine device

What this equipment consists of:

  • The part of the equipment of the machine, where the cutting itself takes place, is called the working bath. Tiles are immersed in this container with water, while the waterjet is cutting the material.
  • The movement system allows you to align structural elements for precise tile cutting, adjusting the pre-set parameters by the user. That allows you to set the desired jet thickness and angle of inclination for cutting.
  • The control panel allows you to remotely control the device and configure all the necessary parameters so that the water cut will cut a predetermined contour on the tile material.
  • The container for abrasive is a steel tank with a sensor that monitors the level of abrasive in the container.
  • Angle head is part of the design with the function of guiding the torch to the desired plane.
  • Control sensors scan the quality of the cut and monitor the bevel on the tile.
  • The abrasive removal device is a special pump that cleans the porcelain stoneware coating from abrasive grit after cutting the material.

How is cutting

For cutting tiles and other finishing materials, a machine is used as a cutting tool, which, using water and an abrasive, cuts various patterns in porcelain stoneware. To do this, high-pressure pumps supply the cutter with water and abrasive, which in turn cut. This technology is based on the principle of erosive influence on the structure of solid materials Sometimes you can hear the name water or water cutting.

The cutting of porcelain stoneware with a machine takes place according to the principle of the effect of a two-phase jet on the particles of the tile, which are knocked out along the cutting line. Thanks to this method, a perfect, even edge of the cut tile is obtained.

The speed of the mixture exiting the cutter is about 1 kilometer per second. That allows you to cut porcelain stoneware without chips and chipping.

Advantages and disadvantages of waterjet cutting

Thanks to the waterjet cutting technology, shaped cutting of porcelain stoneware, intricate patterns and patterns on tiles can be performed. Such equipment is most often used in manufacturing enterprises that offer their services for cutting floor materials.

The floor covering does not heat up during cutting and there are several factors in addition:

  • Waterjet can cut 30 cm thick porcelain stoneware.
  • In the process of processing tiles with an abrasive-water mixture, the edges of the tiles do not turn black and do not melt, as is often the case when working with an electric tool or when laser cutting of porcelain stoneware is performed. Water cutting is capable of cutting thin sheet products.
  • After waterjet cutting, the edge roughness on porcelain stoneware is only Ra6.
  • Cutting safety allows you not to fear for ignition or explosion of the coating during cutting.

But, like any technology, waterjet cutting has its drawbacks, which should be mentioned:

  • Quite a high price of equipment, which entails a high cost of services. In other words, if you need to cut large quantities of porcelain stoneware or create complex panels, the use of waterjet cutting is justified. In everyday situations, when the amount of work is small or you need to cut ordinary tiles, it is easier to use a tile cutter.
  • Limited life of some components.
  • Low speed of cutting sheet material.

Cutting granite is more time consuming than, say, cutting ceramic tiles. But nevertheless, it is better to first correlate the work budget with your financial capabilities. You can find out how to cut porcelain stoneware with simpler tools in a separate article on our website.

Choosing expensive equipment for cutting porcelain stoneware tiles, you should give preference only to those manufacturers whose products are popular and in demand among builders.

Machine device

What this equipment consists of:

  • The part of the equipment of the machine, where the cutting itself takes place, is called the working bath. Tiles are immersed in this container with water, while the waterjet is cutting the material.
  • The movement system allows you to align structural elements for precise tile cutting, adjusting the pre-set parameters by the user. That allows you to set the desired jet thickness and angle of inclination for cutting.
  • The control panel allows you to remotely control the device and configure all the necessary parameters so that the water cut will cut a predetermined contour on the tile material.
  • The container for abrasive is a steel tank with a sensor that monitors the level of abrasive in the container.
  • Angle head is part of the design with the function of guiding the torch to the desired plane.
  • Control sensors scan the quality of the cut and monitor the bevel on the tile.
  • The abrasive removal device is a special pump that cleans the porcelain stoneware coating from abrasive grit after cutting the material.

The principle of the machine

The machine for cutting porcelain stoneware has a rather complex mechanism. A high-pressure pump feeds water and abrasive through special channels into the mixing chamber of the cutter, and from it the ready-made mixture comes out of the carbide nozzle. The jet diameter can vary, depending on the purpose and setting of the machine program, and range from 0.2 to 0.4 mm. The caliber of the nozzle itself has dimensions of 0.5-1.3 mm.

Waterjet cutting is capable of cutting:

  • Limestone.
  • Reinforced concrete.
  • Glass.
  • Composite materials.
  • Hardware.
  • Ceramic tiles.
  • Natural stone.
  • Porcelain stoneware.
  • Marble.

The high-pressure water jet cuts the porcelain stoneware tiles without creating a jagged edge. Due to the design features, the water jet machine is able to cut porcelain stoneware at an angle of 45 ° or more.

READ  How to Cut Tile Without Dust

Unlike a mechanical and electric tile cutter, waterjet cutting of stone is the highest quality work in cutting the finishing material.

Specificity of hydrojet cutting of porcelain stoneware: advantages and disadvantages

There are several technologies for cutting porcelain stoneware. Each of them is convenient for a certain direction and scope of work. For small objects, for example, a bathroom cubicle, a manual tile cutter or a grinder is suitable, and for large halls and retail premises you cannot do without an electric tile cutter. But such a tool can only make straight cuts, but for artistic cutting or creating ornaments, waterjet cutting of porcelain stoneware is used. This is one of the best methods for cutting hard materials. The technology allows you to cut any shapes, drawings, and create a false mosaic.

How is cutting

For cutting tiles and other finishing materials, a machine is used as a cutting tool, which, using water and an abrasive, cuts various patterns in porcelain stoneware. To do this, high-pressure pumps supply the cutter with water and abrasive, which in turn cut. This technology is based on the principle of erosive influence on the structure of solid materials Sometimes you can hear the name water or water cutting.

The cutting of porcelain stoneware with a machine takes place according to the principle of the effect of a two-phase jet on the particles of the tile, which are knocked out along the cutting line. Thanks to this method, a perfect, even edge of the cut tile is obtained.

The speed of the mixture exiting the cutter is about 1 kilometer per second. That allows you to cut porcelain stoneware without chips and chipping.

Advantages and disadvantages of waterjet cutting

Thanks to the waterjet cutting technology, shaped cutting of porcelain stoneware, intricate patterns and patterns on tiles can be performed. Such equipment is most often used in manufacturing enterprises that offer their services for cutting floor materials.

The floor covering does not heat up during cutting and there are several other factors:

  • Waterjet can cut 30 cm thick porcelain stoneware.
  • In the process of processing tiles with an abrasive-water mixture, the edges of the tiles do not turn black and do not melt, as is often the case when working with an electric tool or when laser cutting of porcelain stoneware is performed. Water cutting is capable of cutting thin sheet products.
  • After waterjet cutting, the edge roughness on porcelain stoneware is only Ra6.
  • Cutting safety allows you not to fear for ignition or explosion of the coating during cutting.

But, like any technology, waterjet cutting has its drawbacks, which should be mentioned:

  • Quite a high price of equipment, which entails a high cost of services. In other words, if you need to cut large quantities of porcelain stoneware or create complex panels, the use of waterjet cutting is justified. In everyday situations, when the amount of work is small or you need to cut ordinary tiles, it is easier to use a tile cutter.
  • Limited life of some components.
  • Low speed of cutting sheet material.

Cutting granite is more time consuming than, say, cutting ceramic tiles. But it is still better to first correlate the work budget with your financial capabilities. You can find out how to cut porcelain stoneware with simpler tools in a separate article on our website.

Choosing expensive equipment for cutting porcelain stoneware tiles, you should give preference only to those manufacturers whose products are popular and in demand among builders.

Specificity of hydrojet cutting of porcelain stoneware: advantages and disadvantages

There are several technologies for cutting porcelain stoneware. Each of them is convenient for a certain direction and scope of work. For small objects, for example, a bathroom cubicle, a manual tile cutter or a grinder is suitable, and for large halls and retail premises you cannot do without an electric tile cutter. But such a tool can only make straight cuts, but for artistic cutting or creating ornaments, waterjet cutting of porcelain stoneware is used. This is one of the best methods for cutting hard materials. The technology allows you to cut any shapes, drawings, and create a false mosaic.

The principle of the machine

The machine for cutting porcelain stoneware has a rather complex mechanism. A high-pressure pump feeds water and abrasive through special channels into the mixing chamber of the cutter, and from it the ready-made mixture comes out of the carbide nozzle. The jet diameter can vary, depending on the purpose and setting of the machine program, and range from 0.2 to 0.4 mm. The caliber of the nozzle itself has dimensions of 0.5-1.3 mm.

Waterjet cutting is capable of cutting:

  • Limestone.
  • Reinforced concrete.
  • Glass.
  • Composite materials.
  • Hardware.
  • Ceramic tiles.
  • Natural stone.
  • Porcelain stoneware.
  • Marble.

The high-pressure water jet cuts the porcelain stoneware tiles without creating a jagged edge. Due to the design features, the water jet machine is able to cut porcelain stoneware at an angle of 45 ° or more.

Unlike a mechanical and electric tile cutter, waterjet cutting of stone is the highest quality work in cutting the finishing material.

How is cutting

For cutting tiles and other finishing materials, a machine is used as a cutting tool, which, using water and an abrasive, cuts various patterns in porcelain stoneware. To do this, high-pressure pumps supply the cutter with water and abrasive, which in turn cut. This technology is based on the principle of erosive influence on the structure of solid materials Sometimes you can hear the name water or water cutting.

The cutting of porcelain stoneware with a machine takes place according to the principle of the effect of a two-phase jet on the particles of the tile, which are knocked out along the cutting line. Thanks to this method, a perfect, even edge of the cut tile is obtained.

The speed of the mixture exiting the cutter is about 1 kilometer per second. That allows you to cut porcelain stoneware without chips and chipping.

Machine device

What this equipment consists of:

  • The part of the equipment of the machine, where the cutting itself takes place, is called the working bath. Tiles are immersed in this container with water, while the waterjet is cutting the material.
  • The movement system allows you to align structural elements for precise tile cutting, adjusting the pre-set parameters by the user. That allows you to set the desired jet thickness and angle of inclination for cutting.
  • The control panel allows you to remotely control the device and configure all the necessary parameters so that the water cut will cut a predetermined contour on the tile material.
  • The container for abrasive is a steel tank with a sensor that monitors the level of abrasive in the container.
  • Angle head is part of the design with the function of guiding the torch to the desired plane.
  • Control sensors scan the quality of the cut and monitor the bevel on the tile.
  • The abrasive removal device is a special pump that cleans the porcelain stoneware coating from abrasive grit after cutting the material.

Advantages and disadvantages of waterjet cutting

Thanks to the waterjet cutting technology, shaped cutting of porcelain stoneware, intricate patterns and patterns on tiles can be performed. Such equipment is most often used in manufacturing enterprises that offer their services for cutting floor materials.

The floor covering does not heat up during cutting and there are several other factors:

  • Waterjet can cut 30 cm thick porcelain stoneware.
  • In the process of processing tiles with an abrasive-water mixture, the edges of the tiles do not turn black and do not melt, as is often the case when working with an electric tool or when laser cutting of porcelain stoneware is performed. Water cutting is capable of cutting thin sheet products.
  • After waterjet cutting, the edge roughness on porcelain stoneware is only Ra6.
  • Cutting safety allows you not to fear for ignition or explosion of the coating during cutting.

But, like any technology, waterjet cutting has its drawbacks, which should be mentioned:

  • Quite a high price of equipment, which entails a high cost of services. In other words, if you need to cut large quantities of porcelain stoneware or create complex panels, the use of waterjet cutting is justified. In everyday situations, when the amount of work is small or you need to cut ordinary tiles, it is easier to use a tile cutter.
  • Limited life of some components.
  • Low speed of cutting sheet material.

Cutting granite is more time consuming than, say, cutting ceramic tiles. But it is still better to first correlate the work budget with your financial capabilities. You can find out how to cut porcelain stoneware with simpler tools in a separate article on our website.

Choosing expensive equipment for cutting porcelain stoneware tiles, you should give preference only to those manufacturers whose products are popular and in demand among builders.

Specificity of hydrojet cutting of porcelain stoneware: advantages and disadvantages

There are several technologies for cutting porcelain stoneware. Each of them is convenient for a certain direction and scope of work. For small objects, for example, a bathroom cubicle, a manual tile cutter or a grinder is suitable, and for large halls and retail premises you cannot do without an electric tile cutter. But such a tool can only make straight cuts, but for artistic cutting or creating ornaments, waterjet cutting of porcelain stoneware is used. This is one of the best methods for cutting hard materials. The technology allows you to cut any shapes, drawings, and create a false mosaic.

Machine device

What this equipment consists of:

  • The part of the equipment of the machine, where the cutting itself takes place, is called the working bath. Tiles are immersed in this container with water, while the waterjet is cutting the material.
  • The movement system allows you to align structural elements for precise tile cutting, adjusting the pre-set parameters by the user. That allows you to set the desired jet thickness and angle of inclination for cutting.
  • The control panel allows you to remotely control the device and configure all the necessary parameters so that the water cut will cut a predetermined contour on the tile material.
  • The container for abrasive is a steel tank with a sensor that monitors the level of abrasive in the container.
  • Angle head is part of the design with the function of guiding the torch to the desired plane.
  • Control sensors scan the quality of the cut and monitor the bevel on the tile.
  • The abrasive removal device is a special pump that cleans the porcelain stoneware coating from abrasive grit after cutting the material.

The principle of the machine

The machine for cutting porcelain stoneware has a rather complex mechanism. A high-pressure pump feeds water and abrasive through special channels into the mixing chamber of the cutter, and from it the ready-made mixture comes out of the carbide nozzle. The jet diameter can vary, depending on the purpose and setting of the machine program, and range from 0.2 to 0.4 mm. The caliber of the nozzle itself has dimensions of 0.5-1.3 mm.

Waterjet cutting is capable of cutting:

  • Limestone.
  • Reinforced concrete.
  • Glass.
  • Composite materials.
  • Hardware.
  • Ceramic tiles.
  • Natural stone.
  • Porcelain stoneware.
  • Marble.

The high-pressure water jet cuts the porcelain stoneware tiles without creating a jagged edge. Due to the design features, the water jet machine is able to cut porcelain stoneware at an angle of 45 ° or more.

Unlike a mechanical and electric tile cutter, waterjet cutting of stone is the highest quality work in cutting the finishing material.

How is cutting

For cutting tiles and other finishing materials, a machine is used as a cutting tool, which, using water and an abrasive, cuts various patterns in porcelain stoneware. To do this, high-pressure pumps supply the cutter with water and abrasive, which in turn cut. This technology is based on the principle of erosive influence on the structure of solid materials Sometimes you can hear the name water or water cutting.

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The cutting of porcelain stoneware with a machine takes place according to the principle of the effect of a two-phase jet on the particles of the tile, which are knocked out along the cutting line. Thanks to this method, a perfect, even edge of the cut tile is obtained.

The speed of the mixture exiting the cutter is about 1 kilometer per second. That allows you to cut porcelain stoneware without chips and chipping.

Advantages and disadvantages of waterjet cutting

Thanks to the waterjet cutting technology, shaped cutting of porcelain stoneware, intricate patterns and patterns on tiles can be performed. Such equipment is most often used in manufacturing enterprises that offer their services for cutting floor materials.

The floor covering does not heat up during cutting and there are several other factors:

  • Waterjet can cut 30 cm thick porcelain stoneware.
  • In the process of processing tiles with an abrasive-water mixture, the edges of the tiles do not turn black and do not melt, as is often the case when working with an electric tool or when laser cutting of porcelain stoneware is performed. Water cutting is capable of cutting thin sheet products.
  • After waterjet cutting, the edge roughness on porcelain stoneware is only Ra6.
  • Cutting safety allows you not to fear for ignition or explosion of the coating during cutting.

But, like any technology, waterjet cutting has its drawbacks, which should be mentioned:

  • Quite a high price of equipment, which entails a high cost of services. In other words, if you need to cut large quantities of porcelain stoneware or create complex panels, the use of waterjet cutting is justified. In everyday situations, when the amount of work is small or you need to cut ordinary tiles, it is easier to use a tile cutter.
  • Limited life of some components.
  • Low speed of cutting sheet material.

Cutting granite is more time consuming than, say, cutting ceramic tiles. But it is still better to first correlate the work budget with your financial capabilities. You can find out how to cut porcelain stoneware with simpler tools in a separate article on our website.

Choosing expensive equipment for cutting porcelain stoneware tiles, you should give preference only to those manufacturers whose products are popular and in demand among builders.

In the rubber industry

Waterjet technology is an excellent solution for working with rubber of different densities and thicknesses (up to 300 mm). Cutting takes place at sufficiently low temperature indicators (no more than 90 ° C), so the structure of the material itself does not change and the edges do not melt.

The principle of operation and design of water-abrasive cutting machines

Pressure water cutting equipment operates according to the following principle:

  • passing through the nozzle, the water forms a jet having a diameter of about 0.3 mm, which then enters the mixing chamber;
  • abrasive is simultaneously fed into the mixing chamber, where it is combined with water;
  • the resulting mixture enters another nozzle having a diameter of 0.6 to 1.2 mm;
  • the jet can escape from the second nozzle at a speed of up to 1000 m / s;
  • the mixture jet hits the object to be treated and cuts it.

A bathtub (filled with water) is rigidly fixed on the frame, with supports located at the bottom for placing and fixing the workpiece (mesh, pins, ribs). The cutting head is able to move in 3 planes, can be displaced with a change in the angle of inclination and rotated around an axis.

Water Jet Cutting through 3″ inch thick Aluminum Metal 4′ x 6′

As a result of the operation of the waterjet machine, industrial waste (abrasive, material particles) is formed, which settles to the bottom of the bath. From here they are removed to a special storage tank, where the water is filtered. Sand is cleaned of sludge and reused.

Waterjet cutting machines and equipment

Equipment for waterjet cutting is a special machine that has several structural elements. All of them are necessary to ensure high-quality, accurate and fast cutting in accordance with the existing working drawing. Each work unit is equipped with the following devices:

  • High pressure pump. The speed of the water leaving the nozzle depends on it (processing speed).
  • Power regulator. Wide settings allow you to use abrasive mixtures of different compositions and feed them at different pressures. This makes it possible to process workpieces of different hardness and thickness.
  • Various nozzles (nozzles). Replaced depending on the composition of the mixture of abrasive powder with water and the characteristics of the processed object (thickness and density).
  • Mixer. This equipment is considered the most important unit of a waterjet machine, the operation of which determines the uniformity of proportions and the final quality of the supplied mixture. The result of the cutting process depends on this (accuracy and absence of chips).
  • Water treatment system. The properties of water have a direct impact on the quality of the abrasive mix and the final result of waterjet cutting. The liquid is pre-filtered and cleaned of impurities.
  • Automation. Thanks to automatic systems, the cutting head independently changes the angle of inclination of the nozzle depending on the quality characteristics of the workpiece.

Installations for cutting metal can be equipped with additional: drilling unit, laser positioning and height control system, sludge removal system, abrasive feed and automatic lubrication.

In the aviation and aerospace industry

Waterjet machines have become indispensable for the following tasks:

THIS IS AMAZING, THE WATER CUTS THE STONE! YOU MUST SEE IT!

  • manufacturing of spatially complex parts from titanium, aluminum, zirconium and various alloys;
  • cutting of composite materials without breaking the structure and delamination;
  • production of elements with a complex contour;
  • making closed complex cuts in sheet blanks.

Types of water jet machines and features of their application

There are 2 types of water jet cutting machines:

  • stationary;
  • portable.

Stationary waterjet machines have different principles of manual or programmed control of all parameters.

In devices with manual control, all processing parameters are manually set (angle of inclination, pressure, etc.), they are easy to operate and maintain. They can be used for high-quality and accurate cutting of products with simple geometric shapes.

On CNC waterjet equipment, parts of large thickness and different levels of complexity are produced with the highest precision, with a high-quality surface of the cut being processed. At the same time, the consumption of materials will be minimal. For each product, an individual software is developed that takes into account the parameters of the cutting process: the pressure of the water jet, the composition of the abrasive mixture, etc.

Portable devices are mobile. They are used in fire hazardous industries (gas, oil), as they do not emit sparks during operation. Such equipment is indispensable for the construction of wells, tunnels, as well as for work with hazardous pipelines.

Tips for operating GAR machines

The use of the hydroabrasive method requires compliance with several rules of operation and maintenance:

  • before starting work and turning on the equipment, it is necessary to carry out its visual inspection;
  • work only at positive temperatures;
  • make purchases of spare parts and abrasive materials (garnet sand) exclusively from trusted and reliable manufacturers;
  • carefully monitor the working pressure;
  • keep backup copies of all software (software);
  • when installing and replacing the nozzle, special care must be taken;
  • when starting the jet, make sure that there are no foreign objects in the working area.

Technology and application of waterjet cutting

The method of waterjet cutting of materials has been used for almost half a century in a wide variety of industries. In mechanical engineering, aerospace and aviation industries, in tool making, this method has become indispensable.

In the automotive industry

Waterjet equipment in the automotive industry is used for the following purposes:

  • manufacturing of various plastic parts (dashboards, bumpers, etc.);
  • cutting out decorative elements of the car interior (false ceilings, rugs, etc.);
  • cutting out body parts from thin metal;
  • production of three-dimensional parts with a complex design;
  • cutting laminated glass for cars (triplex).

Paronite

Paronite is made by pressing a mixture of rubber, asbestos, sulfur and a mineral solvent. This mixture is obtained by vulcanizing rubber. It is used as a cushioning material and as a seal for connectors, more often in aggressive environments or at extreme values ​​of pressure and temperature. Mechanical methods of cutting this material lead to the release of asbestos dust into the environment, and only cutting with water will avoid this and get products of arbitrary shape and size.

Cutting porcelain stoneware

Artificial materials, including artificially created stone, are in great demand today among designers and architects of the world. porcelain stoneware. This is the latest finishing material based on acrylic resins, in its properties. hardness and durability. close to natural material and even having a number of advantages over it: artificial stone almost does not know any restrictions on colors, textures and is remarkably combined with almost any design findings.

Glass and mirror

Waterjet cutting technology is the only option for cutting glass and mirrors (other than traditional mechanical methods). So, laser cutting does not allow working with glass at all, because the laser beam passes through the transparent material without destroying it, and it is reflected from the mirror surface. Waterjet cutting is certainly not inferior to diamond cutting, even when only straight cuts are made, but no other technology, except waterjet cutting, allows you to get complex contours.

Cutting marble

Marble is still considered one of the most elite stones in interior decoration. He has amazing beauty, looks expensive and noble. Marble can be painted in a solid color or have a fancy pattern. It lends itself well to processing and polishing. Waterjet cutting from marble can be used to make friezes for finishing swimming pools, fountains, bathrooms, stairs, cornices, fireplace shelves, rosettes, mosaic floors and various souvenirs.

Cutting black steel

A low cutting temperature is the absence of deformation of the workpiece, no melting and burning of the material in the adjacent zone, which is a decisive factor when processing materials that are particularly sensitive to heat, for example, Steel 65G. The absence of thermal influence allows you to cut parts with complex profiles without their subsequent machining.

Waterjet cutting of stone (natural and artificial)

The technology of cutting stone with water allows you to reproduce with high accuracy what the artist has planned. The presence of a coordinate technological table and appropriate software allows you to create compositions from various materials, and complex contour elements of some of them will be combined with a high degree of accuracy with other contours of the same complex shape.

Due to the small cutting width, high precision and repeatability of the cut parts, you can create stone carpets, mosaics, panels, decorate tiles, carefully cut porcelain stoneware slabs of different colors and formats.

Our technology will allow you to embody your ideas in these materials, to create a unique interior in the house or a prestigious image in the office of the company.

Cutting with clean water

Textiles, elastomers, fibrous materials, thin plastics, foodstuffs, paper, thermoplastics and other materials are cut with a jet of clean water reaching a speed of up to 200 m / min. and pressure 3000-4500 bar.

Cutting stainless steel

The cutting tool. water. is also a coolant. The temperature does not rise in the workpiece, since the insignificant heat generated during the cutting process is immediately carried away by the water. Accordingly, the process of waterjet cutting is a cold mechanical destruction of the material, due to which there is no burnout of alloying elements from stainless steel in the adjacent cutting zone.