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our water jet rock cutter
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Water jet rock cutting project
Stone countertops are highly durable, and you can find them in modern kitchens.
Rocks are only of the commonly chosen materials to construct different public buildings and beautiful moments.
Stone walls surrounding a property ensure protection. These stone structures also last long.
Stone bathtubs have a beautiful look. Tub manufacturers use sandstone to design the bathtub.
Fireplaces inside your home are the center of attraction. There are modern homes with stone fireplaces.
Sculptors cut rock pieces to create unique sculptures. Since the ancient age, rocks have had their use in the field of art.
Water jet rock cutter with customized solutions
You may not easily make the right choice for your rock-cutting needs. Our team is there to help you in the best way.
You can choose our high-quality pump to operate your water jet rock cutting systems.
Our professionals will let you use some additional kits to increase the productivity level of your manufacturing business,
The control systems available to us are Ncstudio, Beckhoff, and IGEMS. You have to choose the right one for better productivity.
We can provide you with a perfectly customized work table. You have to inform us about the dimension of your raw material.
How to buy our water jet rock cutter
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We will customize your water jet rock cutting system. Get the best solution from us.
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You will get value from the efficiency level of our water jet rock cutting system.
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The ultimate guide to FAQs
water jet rock cutting machine
1. Is a waterjet rock cutter a user-friendly system?
Yes, a waterjet rock cutter can be user-friendly. Firstly, the abrasive waterjet cutting method cuts the granular abrasive and then sets it in the water stream. The granular abrasive now accelerates the cutting stream power and enables the easy cutting of hard materials like rock.
Besides, it can execute quality cutting performance on materials that are a maximum of 200 mm thick. Unlike other types of cutting technologies, water jet rock cutters do not produce hazardous waste like fumes and gases. Hence, this makes this both environmentally friendly and user-friendly.
2. Which industries use water jet rock cutters?
With the origin of this high-pressure technical tool, harder rocks are susceptible to the water jet method. This opens a new era in the multiple industries of mining, civil engineering, quarrying, waste treatment, mineral processing, and reclamation. The artists and engineers of these domains now can take advantage of its smooth and burr-free cutting to give different shapes and designs to rocks.
3. How does a water jet rock cutter work?
Waterjet rock cutters use high-pressure and low-volume in recent times with the development of high-pressure pumps. It uses several approaches to give a quality cutting performance. The most straightforward approach is the use of a high-pressure water jets cutter between 2,000 to 50,000 psi to disintegrate the whole rock face. This traditional approach offers a much lower efficiency of removing rocks.
The next method is the induction of cavitation bubbles in the water jet stream. When these cavitation bubbles tumble on the surface of the rock, the velocity of rock corrosion gets enhanced. Another method used for using a water jet rock cutter is the breaking of the continuous water jet into water packets. The pressure created by this action leaves a greater impact on eroding rocks than the static pressure.
The new abrasive approach shows a remarkable technique. With the introduction of the abrasive particles into the water jet stream, the particles begin to accelerate close to the rate of the jet.
4. What abrasives need to be used in water jet rock cutting?
The technology of abrasive waterjet cutting is a promising way to excavate rocks as it requires accurateness in construction with low vibration. The abrasives needed for use in the water jet cutting are hardness, toughness, specific shape, and density.
Water jet rock cutters require a balance between their cutting speed and component wear. If you use a soft abrasive, it can expand the nozzle life. However, it slows down the rate of cutting.
A hard abrasive can offer a faster cutting experience but wears off the nozzle quickly. Almandine garnet can effectively make a balance between faster cutting and better nozzle life.
The primary force of cutting is the role of the mass multiplied by the acceleration. An ideal abrasive has the heaviest particle to accelerate the water stream to its maximum rate and offer a higher cutting force.
Toughness plays a straightforward function in the performance of the waterjet abrasive. A friable material breaks down, while tough materials can get tangled up during the process of mixing.
So, it is ideal to use abrasives with a measured ratio of breaking and produce sharp and angular rock cutting edges.
● Particle Shape
There is vast availability of different particle shapes of abrasives that one can imagine. Be it perfect beads, razor-sharp or needle-like crystals, abrasives are available in all types.
It is vital to recognize the sphere to carry out the mass project in a high-powered water stream. Remember, there needs to be a constant balance between cutting, acceleration, and wear.
5. What factors are important while purchasing water jet rock cutters?
While purchasing water jet rock cutters, you must consider some crucial factors.
- Versatile Cutting Range
A versatile cutting range can help in cutting multiple rock sizes and other hard materials.
- Quality Cutting
Consider a water jet rock cutter that offers a good quality cutting with smooth kerf and no rough edges.
- Non-Heating Process
Water jet rock cutters need abrasives that may produce no or very little heat during the processing.
- Environmental Friendly and User-Friendly
Choose the cutter which generates little or no hazardous wastes or toxic gas during the process.
- Reduction in Adjustment
A reduction in adjustment helps to get rid of the troubles caused by the tricky clamping.
- Cost: The main factor that one must keep in mind while purchasing water jet cutters is water jet cost.
- Water Cost
The cost of water is the cheapest factor you have to consider in the water jet cost, though it is a prominent performer in the process. Without water, it is impossible to use a water jet for cutting.
The amount of water you may need to use depends directly on the material quantity. The thicker the material, the more water will be needed.
- Power Cost
Waterjet requires electricity to get the power to work on, and therefore it plays a significant role in contributing to the cost of the water jet.
- Wears Cost
Consider the cost of replacing wear parts, including focusing tubes, pump seal orifice, or other parts. Calculate these wears on the basis of cost-per-hour, and you will get an idea of total costing.
- Abrasive Cost
Most of the cost will be taken off by abrasives. The hard rock abrasives help to erode larger garnet rocks into smaller precise mesh sizes quickly. The alluvial garnet has round grains, which flower the cutting process. Moreover, hard rock abrasives are more expensive than alluvial abrasives.
6. Do I need to polish the rock after cutting it with a waterjet cutting machine?
Usually, you do not require to go for additional polishing after cutting the rock with the help of a water jet cutting machine. As we use the abrasive water jet cutting method to cut rocks, it offers a fine cutting experience.
In short, it depends on the type and size of the rocks to confirm whether you need to polish the rock after cutting it with a water jet cutting machine.
7. What are the most effective tips for using water jet rock cutting systems?
Remember, waterjet cutting needs high pressure that can go up to 6200 bar resulting in 1000 m/soutlet speed. For cutting rocks, an addition of abrasives comes in use to carry out the process.
Next is to derive the optimal use of the pump. You need to give specific treatment to water. Plus, the sound pressure may increase up to 12 dB during the water jet cutting. So, do not also forget to take that into account.
Emissions can be reduced if you carry out water jet cutting underwater.
8. Is there a risk of damage to the piece of rock for cutting with the waterjet cutter?
Water jet rock cutting is mainly used in various industries to erode a natural stone and form it into custom shapes. Waterjet cutting uses a more assertive approach than conventional laser cutting tools.
The idea behind this is to work with a more high-pressure water jet to create precise shape and design with easy maintenance at a lower cost. We can say that the risk factor of damage to the piece of rock while cutting with the waterjet cutter is much frailer than other tools.
Hence, the water jet rock cutter gives rise to endless creative opportunities for engineers and artists of different fields.
9. How will I solve the complications with my water jet rock cutting system?
While using a water jet rock cutter, there may arise several complications. Here are some common complications that may arise along with their solutions.
Irrespective of the direction of over stroking, the first step you should take is resetting the alarm.
● Turn off its cutting head.
● Turn the pump on and let the pressure build
● Now turn the cutting head
● Lastly, observe the intensifier stroke velocity through the indicator or proximity switches.
If you find water leakage in the weep hole present on the output adapter, it may be due to loose high-pressure water tube fitting or cracked end of the tube. It can even be because of a failed output adapter.
In such cases, you must think of replacing the high-pressure water seal.
Short Seal Life
If the high-pressure seals seem to have a shorter life, you can take the following measures to increase their intervals.
● Keep the water quality under a reasonable range.
● Check whether the volume and pressure of water are meeting their minimum requirements.
● Clean the parts to keep them free from debris
● Monitor visible cracks on the high-pressure cylinder
Failure of Hydraulic Pressure
If your pump fails to generate hydraulic pressure, double-check its pressure regulating knob. Separate the pump compensator for verifying the increase of the pump pressure from the pressure regulating circuit. Measure the hydraulic relief valve temperature to check it is sealed.
Lower Water Pressure
If you see the water pressure falling, verify the orifice. If you see defects in the orifice, replace it. Check if there is any leak in the regulator valve. If you see a leak, repair it.
If the intensifier stroke, examine the high-pressure tubing for leakage. Again replace or repair them. Additionally, make sure that the condition of the high-pressure and the low-pressure poppets are satisfactory. Otherwise, replace or repair them.
10. What benefits do you get from water jet rock cutters?
Water jet rock cutters are beneficial in many ways.
● No Cutting limits. Waterjet cutters can efficiently cut and erode rocks with less vibration.
● No HAZ. The no Heat Affected Zone offers clean cutting and increases the safety of the operators by eliminating the burning risk.
● No material contortion. The use of the cold cutting process enables fine and burr-free cutting without distorting the material.
● No extra finishing process. It saves time as the high-quality cutting ensures providing an accurate result. Consequently, it enhances overall efficiency.
● No toxic waste. Water jet rock cutters give importance to a healthy environment. It does not generate fumes or toxic gases that can pollute the environment.
11. How much accuracy can you maintain with water jet rock cutting systems?
Relatively, a water jet rock cutter offers high accuracy. Once the process of cutting begins, a water jet cutter can accomplish +/-0.001″ parts tolerance, maintaining consistency. This makes the device highly suitable for getting precision in cutting.
Nonetheless, there are some more factors that can possibly affect gaining accuracy while cutting with a water jet rock cutter. These factors include material thickness, accurate controlling system, and low production of heat with parts tolerance.
12. How should I choose the right water jet rock cutting system?
Selecting the ideal water jet cutting system can make a vast difference in the operation and profitability of the device.
● Versatile Cutting
A versatile water jet cutter may assist in cutting several rock densities and mold them in different sizes and designs.
● Cutting Quality
Evaluate the quality of the water jet rock cutter as it will help in achieving smooth kerf with no rough and uneven edges.
Water jet rock cutters operate with the help of abrasives that usually generate no to minimal amount of heating during the process.
13. Is your waterjet cutter efficient in cutting rock perfectly?
The water jet rock cutter is one of the most innovative technologies, which began as an expensive method of cutting rock. However, the cutter is actually inexpensive and may save money in several situations.
The water jet rock cutter can give specific shapes and designs more efficiently than other rock-cutting machines.
14. What is the cost of operating water jet rock cutters?
There are various consumables, different types of power requirements, the price of water, and especially the expense of abrasives that goes behind the operation costs. Here are two essential parts that occupy the heart of water jet machine operation.
Cutting table – The cutting table is the place to keep the material for performing the cutting process. Accordingly, it is the size of the cutting table that drives the cost.
Waterjet pump – The pressurized water that leads to high-pressure pressure in the pump also adds up to the cost.
Different factors affect the running cost of a water jet rock cutter. It may cost between $20 per hour to $40 per hour on average to operate a water jet rock cutter if we take a solo abrasive water jet cutting head at around 60000 psi.
15. How much do you need to invest in operating water jet rock cutters?
Basically, it is the cost of the pump and water jet cutting table that drives the capital expenses of the investment.
Plus, you need to consider the following expenses for operating the water jet rock cutter.
● Water Cost: The quantity of water that you may require depends solely on the quantity of the material. If you choose a thicker material, you will need more water and vice-versa.
● Power Cost: Water jet rock cutters need electrical power to perform the work.
● Wears Cost: Make a count of the wears on cost-per-hour to get a notion of the entire cost.
● Abrasive Cost: Among the operating costs, abrasives hold the maximum investment.
16. What are the sizes of waterjets rock cutters?
Waterjets have different nozzle sizes, which can provide different amounts of pressure for rock cutting. Normally, the diameters of nozzles vary between 0.023 inches to 1.0 inches. In the case of a nozzle whose diameter is 0.023 inches has a pressure range between 5,000 PSI to 25,000 PSI. Moreover, it can cover around 2.0 inches to 4.0 inches of stand-off distance within 0.1 to 5.0 seconds.
17. How much water pressure is needed to cut rock with waterjet cutters?
People use low-pressure, high-volume water jets for the erosion of rocks that have loose consolidation. Low-volume, high-pressure waterjets for cutting rock is a recent development. They have water pumps of high-pressure of around 2,000 PSI to 50,000 PSI or 13.8 MPa to 344.7 MPa. This system is highly beneficial for use; however, its application is not widespread. For effective cutting, the waterjet must direct itself accurately into the area of impact.
18. How fast can a waterjet cutter cut the rock?
Water jet rock cutters can cut at traverse speeds between 0.002 to 5.5 ft/sec. It can cut at this speed with nozzle pressures ranging from 1000 to 60,000 lbf/in sq. The minimum diameter of this nozzle must be around 0.008 to 0.015 in. These test results were on the basis of materials like Indiana limestone, Barre granite, and Berea sandstone.
19. How much rock thickness can be handled by waterjet cutters?
There is a misconception around waterjets. Some say abrasive jets cannot cut thick rocks. However, they can cut over a foot of any type of rock. However, while cutting thicker rocks, their speed will be a bit slower. Waterjets can further rough out rocks that are 24” thick. Thus, it saves the time of milling.
20. Why are water jet rock cutters better than other cutting systems?
Apart from rocks, waterjet cutters can cut through materials like ceramics, plastics, metals, rubber, glass, and ceramics. As it has a cold cutting method, there is no HAZ or heat-affected zone. This enhances operator safety by reducing burn risks and makes clean cuts. Additionally, it does not require any extra finishing process, which increases efficiency and saves time. Lastly, it is better than other cutting systems as it is an environment-friendly process that reduces hazardous wastes.
21. How is the edge treatment quality for water jet rock cutters?
Water jet rock cutters are particularly famous for their smooth edge treatment quality. Thus, it becomes precise. This enables it to reduce wastage in the form of fumes that can be harmful to the environment. And, it requires little blade maintenance in terms of replacing, sharpening, and switching. Hence, its superior edge finishing makes it energy-efficient.
22. What are the major parts of your water jet rock cutters?
The main parts of a water jet rock cutter are a high-pressure pump, waterjet nozzle and table, catcher tank, and control unit. Motion equipment is also present. The pump enhances water pressure and brings it towards the nozzle. This will enable the water jet to come out from the cutting head. The control units contain programs that help to control the motion of the head. Motion equipment enables the cutting head to move across the table of the waterjet freely. The catcher tank collects and neutralizes the abrasives and the used up water during the process of cutting.
23. How do you use water jet rock cutting machines for the growth of your business?
A water jet rock cutter can meet the needs of customers. Moreover, it enhances the reliability of the technique of manufacturing. You can further process any kind of material with this machine. Besides, it rarely faces any disruption. Many big industries demand the use of waterjet cutter machines these days. Thus, it will be a good investment for the growth of your business.
24. Does a water jet rock cutter cause burrs on the material?
Water jet rock cutters remove burrs from pre-drilled holes and cut surfaces. It further eliminates burrs from blind holes, complex cavity-like shapes, and narrow openings. Water jet rock cutters control the processing parameters by removing micro-sized and large size burrs. Glass beads, alumina, and silicon carbide in waterjets also enhance the deburring process.
25. Does a water jet rock cutter work better than a laser cutter?
Water jet rock cutters do not need heat. And sensitive materials are free from warps. It provides clean cuts which eliminate the need for sanding or grinding. Their low costs and easy automation make them suitable for high productions. Laser cutters, on the other hand, may cause warping in sensitive materials and bend because of high temperatures. This is why water jet rock cutters are better than laser cutters.