What Are The Consumable Parts Of Abrasive Waterjet Cutting Machine? How To Maintain Tt?

What Are The Consumable Parts Of Abrasive Waterjet Cutting Machine? How To Maintain Tt?

The water Jet Cutting Machine (also known as Abrasive Water Jet Machining) uses ultra-high pressure Waterjet Garnet to carry abrasive (such as garnet sand) to cut workpieces. Its working principle is simply as follows: the high-pressure pump increases the water pressure to tens of thousands of psi, forming a high-speed water flow through the nozzle; at the same time, the abrasive is introduced into the gem sand tube (303565-High-Quality-Waterjet-Cutting-Machines-Parts-p.html target='_blank'>WS2529-Water-Jet-Parts-For-Sale-p.html target='_blank'>Mixing Chamber), so that the water flow carries the abrasive to produce a high-energy jet to cut metals, ceramics, stones and other materials. Because this cutting method does not produce a heat-affected zone, it is often used in industries such as aerospace, automobile manufacturing, and stone processing.

Common wearing parts of Abrasive water jet cutting machine

Nozzle (high-pressure nozzle)

Function: The nozzle, also known as the nozzle, is a key component of water jet cutting, responsible for focusing and ejecting the high-pressure water jet. The nozzle is usually made of materials such as carbide or diamond.
Cause of wear: During the cutting process, the inner wall of the nozzle is subjected to the impact of ultra-high-pressure water flow and the abrasive carried for a long time. The abrasive particles constantly wipe the nozzle 20431118-Waterjet-Parts-In-Stock-p.html target='_blank'>20431118-Waterjet-Parts-In-Stock-p.html target='_blank'>Orifice, causing the inner diameter of the nozzle to gradually increase and the orifice to deform. The worn nozzle will reduce the water flow rate and focusing effect, which will directly affect the cutting accuracy and efficiency.
Typical life: The nozzle life varies greatly due to material and working conditions. Generally speaking, the service life of ruby or MJ0110020-Abrasive-Waterjet-Cutting-Machine-Parts-p.html target='_blank'>Sapphire Nozzles is mostly about 40 to 80 hours, while diamond nozzles are harder and can reach hundreds of hours or even longer under normal maintenance.
Replacement Note: It is recommended to check the nozzle condition regularly. If the orifice is obviously worn, the outlet is deformed, or the cutting quality is reduced, it should be replaced in time. When installing a new nozzle, avoid impact and scratches, and tighten it with a special wrench to ensure that the nozzle is aligned with the cutting head. Before use, the nozzle opening can be cleaned with water to remove residual impurities and reduce the risk of clogging.

Gem sand tube (WS0202-Abrasive-Water-Jet-Parts-In-Stock-p.html target='_blank'>Focusing Tube/Mixing Chamber)

Function: Gem sand tube, also known as focusing tube or mixing chamber, is a key component after the nozzle. It has a built-in wear-resistant 1-11024-High-Pressure-Waterjet-Parts-In-Stock-For-Sale-p.html target='_blank'>Seal-Bushing-Assembly-80086630-Water-Jet-Parts-In-Stock-p.html target='_blank'>Bushing (usually ruby or sapphire) to mix the high-pressure water flow with the abrasive and further focus it, so that the abrasive is evenly distributed in the water jet and enhances the cutting ability.
Wear cause: When the abrasive carries water through the mixing chamber, it will cause continuous wear on the bushing inside the tube. After long-term use, grooves or cracks will appear on the bushing wall, resulting in reduced focusing effect. Foreign matter, feed blockage or poor alignment will also accelerate wear.
Typical life: In general, the life of the gem sand tube is about 500 hours. The actual life depends on factors such as abrasive quality, cutting pressure and workpiece hardness. High-quality abrasive and stable feed help to extend the life of the sand tube.
Replacement Note: When replacing the sand tube, be careful to prevent collision with hard objects, align the center axis of the cutting head during installation, and ensure that the bushing is in the correct position. Every time you change the nozzle, you can check the wear of the sand pipe at the same time. If you find that the bushing is cracked or the aperture is significantly enlarged, you should replace it in time. Keeping the mixing chamber clean and the filter device intact can also effectively delay wear.

Wear-resistant tube (high-pressure pump cylinder)

Function: In some water jet cutting machines, the high-pressure pump (booster pump) is equipped with a wear-resistant tube (also called pump cylinder or cylinder sleeve), which is usually made of special coating or carbide material. The wear-resistant tube works closely with the plunger to withstand the reciprocating motion and high-pressure impact of the plunger, and plays a guiding and 3HAC022379-001-Axis-2-3-For-Robot-Water-Jet-Cutting-Machine-Parts-In-Stock-p.html target='_blank'>Sealing role.
Cause of wear: Over time, wear will occur between the plunger and the pump cylinder, especially when the pump oil quality is poor, there are many impurities in the water or insufficient cooling. The worn pump cylinder will cause the 301639-High-Quality-Waterjet-Cutting-Machines-Parts-p.html target='_blank'>Seal Ring to wear more, causing leakage or pressure decay.
Typical life: Pump cylinders usually have a long life of up to several thousand hours. However, the specific life is greatly affected by the intensity of use and maintenance. When the pump body leaks or the pressure drops, the pump cylinder wear should be checked in time.
Replacement Note: When replacing the pump cylinder, the pump needs to be disassembled, and the process is relatively complicated. It is recommended to be operated by professional technicians. Before installing a new pump cylinder, the plunger surface should be cleaned to avoid impurities or scratches. After installation, the seal compression should be readjusted to ensure no leakage. Pay attention to using 3HAC032140-004-TMO-150-For-Robot-Water-Jet-Cutting-Machine-Parts-In-Stock-p.html target='_blank'>Lubricating Oil that meets the manufacturer's specifications and regularly replace the oil-water separator to protect the pump cylinder and seals.

High-pressure seals

Function: High-pressure seals usually refer to seals installed at booster pumps or cutting heads, which are used to withstand extremely high water pressure and prevent water pumps or cutting heads from leaking. These seals are mostly made of materials such as polytetrafluoroethylene and fluororubber, and are required to be resistant to high pressure and wear.
Wear causes: During the operation of the water jet, the seals are affected by plunger impact, pressure fluctuations and water temperature changes, and are prone to material fatigue and indentation over a long period of time. Once worn, the sealing performance will be reduced, and intermittent or continuous leakage will occur. If warm water leaks in the water jet system, it often means that the high-pressure seal has failed and needs to be replaced in time. Worn seals may also cause pump stroke over-stroke, so special attention should be paid to detection.
Typical life: The life of the high-pressure seal depends on the operating conditions, generally between hundreds and one or two thousand hours. Under normal circumstances, many users will replace the seal every 6 months or 1,000 hours according to the equipment instructions to prevent accidental leakage. When it is found that the pump body is dripping, pressure is difficult to establish, or there is water in the oil, the seal should be replaced.
Replacement precautions: When replacing the seal ring, the pump body should be completely drained of water pressure and disassembled according to the manufacturer's manual. Use a clean working environment and tools, and carefully install the new seal ring to avoid scratches. When replacing, check whether the seal groove, retaining ring and other matching parts are intact. After installation, perform a low-pressure leak test to confirm that there is no leakage before resuming production. Regular replacement of the seal ring is an important part of water jet cutting machine maintenance, which can effectively avoid damage to the pump body.

High-pressure pipeline system

Function: The high-pressure pipeline system includes high-pressure steel pipes, high-pressure hoses, joints, valves, etc., which are used to carry high-pressure waterways and safely transport the high-pressure water produced by the booster pump to the cutting head.
Wear causes: High-pressure pipelines are subjected to extremely high water pressure for a long time, and are prone to tiny cracks, fatigue damage or loose joints. Poor quality or aging pipes will accelerate damage under high pressure impact. In addition, high water hardness or impurities will also corrode the inside of the pipeline, increasing the risk of wear.
Typical life: Referring to industry experience, the typical life of high-pressure pipelines and connectors is about 2,000 hours. However, if they are improperly maintained or the operating environment is harsh, their life may be significantly shortened. Regularly checking the pipeline status and tightening the joints in time are necessary maintenance measures.
Replacement Note: When replacing high-pressure hoses or pipe fittings, avoid sharp bends and over-tightening to prevent stress concentration. For threaded pipe fittings and valves, thread sealing tape or sealant should be used after each disassembly and assembly, and check whether they are tightened in place. Use original or verified high-pressure pipe fittings to ensure that the material meets the pressure resistance requirements. For steel pipes used for a long time, consider regular non-destructive testing (such as magnetic particle inspection and pressure testing) to ensure safety.

Waterjet maintenance recommendations

In order to extend the service life of the above-mentioned wearing parts and ensure stable operation of the equipment, the following maintenance measures are recommended:
Clean the cutting head and filter regularly: Clean the inside of the cutting head before and after each shift to remove sand and impurities; regularly replace or clean the water inlet filter to ensure clean water. Good water quality and a clean environment can significantly reduce wear.
Use high-quality abrasives: Use garnet sand with uniform particle size and appropriate hardness to improve cutting efficiency and reduce scouring of the nozzle and sand pipe. Adjust the abrasive flow rate not too much or too little to maintain a stable cutting effect.
Monitor water quality and water pressure: Ensure that the incoming water meets the equipment requirements (hardness ≤100ppm, etc.), and use softened water or reverse osmosis equipment when necessary. Avoid running the water pressure too high or too low, keep the instrument pressure stable, and reduce the damage of shock waves to seals and pipelines.
Check and replace wearing parts in time: Make a replacement plan based on actual usage. Check the wear of the sand pipe every time the nozzle is replaced; the Sealing ring should be replaced on schedule or immediately deal with leakage when it is found; the high-pressure pipeline and valve joints should be checked regularly to prevent loosening and leakage. Spare parts are sufficient to prevent unexpected shutdowns.
Standardized operation training: Operators should receive professional training and master the correct startup, cutting and shutdown steps. Avoid operations such as no-load high-pressure startup, frequent stroke over-stroke, and violent collision of the cutting head to reduce additional wear.
Good lubrication and cooling: Lubricating oil should be replaced regularly as required, and the oil and water separator in the water pump should be kept clean. Ensure that the cooling system of the booster pump works normally to prevent overheating from accelerating the aging of the seal.

Through the above maintenance strategies, the wear rate of the consumable parts of the sand-adding water jet cutting machine can be effectively delayed, the failure rate can be reduced, and the production efficiency and cutting quality can be improved.