Abrasives are still the largest cost driver for water jet cutting, and any measures taken by the shop to reduce Abrasive consumption can have a major impact on the cost of each part.
Here are three ways to reduce abrasive consumption.
Adjust cutting equipment
First, the shop should use a smaller water nozzle/abrasive nozzle combination. Typically, the shop cuts with 0.014 inch water nozzles and 0.040 or 0.043 inch abrasive nozzles, consuming 1.2 to 2 pounds of abrasive per minute. By reducing the size of the water/abrasive nozzle combination to 0.010 inch/0.030 inch, the abrasive consumption drops to approximately 0.75 to 0.9 pounds per minute.
However, most workshops are not willing to reduce the size of the water/abrasive nozzle combination because it means that the number of parts produced per hour is reduced. This is true, but not when the shop uses two cutting heads on its system.
Cutting with two cutting heads and a smaller nozzle combination not only results in more parts per day but also lower abrasive costs per part. Unfortunately, due to the size of the parts, not all parts are suitable for double-headed cutting. However, for a 5-foot X 10-foot or larger machine table, most shops find that the second grinding head is available for most of the time.
For example, if the shop uses a 0.014 inch/0.040 inch nozzle combination, a single grinder cuts at 20 ipm and consumes 2 pounds of abrasive per minute, on the same shop, using a 0.010 inch/0.030 inch combination of nozzles, can achieve 12 ipm. Rate cutting consumes only 1 pound of abrasive per minute and results in similar cut quality. However, using a dual-grinding head in the same shop effectively cuts at 24 ipm (2 X 12 ipm) and consumes 2x1 pounds of abrasive per minute.
If the cost per pound of abrasive is 25 cents, the cost of the smaller nozzle combination is $0.021 per inch. The larger nozzle combination costs $0.025 per inch. The cost savings per inch is 16%, and these percentage points accumulate quickly when you consider how many cuts you make in the workshop each year.
For the machine booster pump, most of it is either 50 horsepower 1.0 gpm (gallons per minute) or 100 horsepower 2.0 gpm. A 50-horsepower pump assisted the shop in running a single grinding head with a 0.014-inch water nozzle at a pressure of 55,000 psi, or a dual grinding head with a 0.010-inch nozzle operating at a pressure of 55,000 psi. A 100-hp water pump can operate a 0.014-inch dual-head at 55,000 psi or up to four 0.010-inch heads at 55,000 psi.
Another alternative is to use a 60 HP pump with a water output of 1.2 gpm to 1.3 gpm. The advantages of these pumps are the ability to operate a dual grinding head with a 0.011 inch water nozzle at a slightly higher speed than a 0.010 inch grinding head, and even if it increases the abrasive consumption, it is not noticeable because 0.030 is still being used. Inch abrasive nozzle. In addition, the 60 HP pump consumes less power than the 100 HP pump.
Determine the amount of abrasive
Numerically controlled abrasive measurement is the second method of reducing abrasive consumption. These CNC abrasive measurement systems allow the shop to change the feed rate of the abrasive during the cutting operation and to choose between "mass" cutting and "yield" cutting. Mass cutting uses less abrasive than production cutting.
If the part requires high-quality cutting in a specific area, and other areas can take higher-speed, lower-quality cuts, the shop can use abrasives to measure the area with higher abrasives and save more per minute. 0.2 to 0.4 pounds of abrasive. Moreover, the NC abrasive measurement enables the shop to reduce the amount of abrasive used during the part piercing process by 50% or more without increasing the piercing time.
Keep the collection tank clean
Finally, the abrasive removal system can reduce part costs by eliminating the downtime needed to clean the machine's abrasive from the trap tank. The abrasive removal system automatically removes abrasive material as the machine cuts.
Finally, it is worth mentioning that if the water charges in the workshop are high, closed-loop water circulation systems can be used to cut costs. These systems also eliminate the potential for clogging of the effluent pipes by the effluent pipes. They improve the quality of the water flowing to the machine's pump, so the pumps are more durable.
Here are three ways to reduce abrasive consumption.
Adjust cutting equipment
First, the shop should use a smaller water nozzle/abrasive nozzle combination. Typically, the shop cuts with 0.014 inch water nozzles and 0.040 or 0.043 inch abrasive nozzles, consuming 1.2 to 2 pounds of abrasive per minute. By reducing the size of the water/abrasive nozzle combination to 0.010 inch/0.030 inch, the abrasive consumption drops to approximately 0.75 to 0.9 pounds per minute.
However, most workshops are not willing to reduce the size of the water/abrasive nozzle combination because it means that the number of parts produced per hour is reduced. This is true, but not when the shop uses two cutting heads on its system.
Cutting with two cutting heads and a smaller nozzle combination not only results in more parts per day but also lower abrasive costs per part. Unfortunately, due to the size of the parts, not all parts are suitable for double-headed cutting. However, for a 5-foot X 10-foot or larger machine table, most shops find that the second grinding head is available for most of the time.
For example, if the shop uses a 0.014 inch/0.040 inch nozzle combination, a single grinder cuts at 20 ipm and consumes 2 pounds of abrasive per minute, on the same shop, using a 0.010 inch/0.030 inch combination of nozzles, can achieve 12 ipm. Rate cutting consumes only 1 pound of abrasive per minute and results in similar cut quality. However, using a dual-grinding head in the same shop effectively cuts at 24 ipm (2 X 12 ipm) and consumes 2x1 pounds of abrasive per minute.
If the cost per pound of abrasive is 25 cents, the cost of the smaller nozzle combination is $0.021 per inch. The larger nozzle combination costs $0.025 per inch. The cost savings per inch is 16%, and these percentage points accumulate quickly when you consider how many cuts you make in the workshop each year.
For the machine booster pump, most of it is either 50 horsepower 1.0 gpm (gallons per minute) or 100 horsepower 2.0 gpm. A 50-horsepower pump assisted the shop in running a single grinding head with a 0.014-inch water nozzle at a pressure of 55,000 psi, or a dual grinding head with a 0.010-inch nozzle operating at a pressure of 55,000 psi. A 100-hp water pump can operate a 0.014-inch dual-head at 55,000 psi or up to four 0.010-inch heads at 55,000 psi.
Another alternative is to use a 60 HP pump with a water output of 1.2 gpm to 1.3 gpm. The advantages of these pumps are the ability to operate a dual grinding head with a 0.011 inch water nozzle at a slightly higher speed than a 0.010 inch grinding head, and even if it increases the abrasive consumption, it is not noticeable because 0.030 is still being used. Inch abrasive nozzle. In addition, the 60 HP pump consumes less power than the 100 HP pump.
Determine the amount of abrasive
Numerically controlled abrasive measurement is the second method of reducing abrasive consumption. These CNC abrasive measurement systems allow the shop to change the feed rate of the abrasive during the cutting operation and to choose between "mass" cutting and "yield" cutting. Mass cutting uses less abrasive than production cutting.
If the part requires high-quality cutting in a specific area, and other areas can take higher-speed, lower-quality cuts, the shop can use abrasives to measure the area with higher abrasives and save more per minute. 0.2 to 0.4 pounds of abrasive. Moreover, the NC abrasive measurement enables the shop to reduce the amount of abrasive used during the part piercing process by 50% or more without increasing the piercing time.
Keep the collection tank clean
Finally, the abrasive removal system can reduce part costs by eliminating the downtime needed to clean the machine's abrasive from the trap tank. The abrasive removal system automatically removes abrasive material as the machine cuts.
Finally, it is worth mentioning that if the water charges in the workshop are high, closed-loop water circulation systems can be used to cut costs. These systems also eliminate the potential for clogging of the effluent pipes by the effluent pipes. They improve the quality of the water flowing to the machine's pump, so the pumps are more durable.
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