In this article we will discuss about:- 1. Meaning of Robotized Water Jet Cutting 2. Characteristic of Robotized Water Jet Cutting Process 3. Advantages.
Meaning of Robotized Water Jet Cutting:
Robotized water jet cutting is a versatile, cost-effective method for shaping products made of plastics, composites and certain sandwich materials. Combined with advanced robot technology, water jet cutting supports frequent model changes and just-in-time deliveries. Other benefits are smooth production, high quality and high precision.
Greater cost-effectiveness is made possible by the superior flexibility of robotized water jet cutting. This is important for just-in- time deliveries in the automotive industry, particularly in the production of different models with ranges of variants.
Characteristic of Robotized Water Jet Cutting Process:
(i) Robotized water jet cutting involves water being forced under very high pressure through a nozzle with a small diameter. The robot arm guides the thin water jet according to a predetermined pattern close to the workpiece.
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(ii) The cutting box is an enclosed modular production cell, especially designed for robotized water jet cutting. The modules are extremely flexible, and several cutting boxes can be easily combined in series to form an automated system. Programs and products can be exchanged between the different cutting boxes.
(iii) A water pressure of nearly 4000 bar is used.
(iv) A thin water jet reduces energy consumption, and a larger jet can reduce cycle times.
(v) The nozzle is of high-grade sapphire or diamond. The life of the simpler sapphire nozzle is about 75 hours, after which the water jet starts to become deformed.
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(vi) The water leaves the nozzle at twice the speed of sound.
(vii) No deformation occurs and moisture is not a problem.
(viii) The cutting boxes reduce the sound emissions.
(ix) Only simple fixtures are normally needed.
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(x) A safety zone with light barrier protects personnel.
(xi) The programming of the movements of the robot arm and water jet is the key to successful robotized water jet cutting.
(xii) Three-dimensional CAD drawings may be used as water jet cutting programs.
(xiii) Water jet cutting for just-in-time deliveries.
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(xiv) New cutting programs are created in a short time.
(xv) Changeover to different models and variants is accomplished simply by changing the programs and fixtures.
Advantages of Water Jet Cutting over Traditional Punching and Manual Cutting:
(i) Change-over to another product or product variant can take place during the work cycle; no set-up time is necessary. Production and the product can be more easily adapted to specific customer requirements. This makes just- in-time deliveries possible.
(ii) The operator can quickly and simply reprogram the movements of the robot arm holding the water jet for new or modified products. Production downtime as a result of modification of a new model is limited to hours instead of days or weeks.
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(iii) Parts made of new, soft materials with irregular shapes that are difficult or even impossible to punch out can be cut with a high quality, since the robot-controlled nozzle cuts in all planes.
(iv) Cutting is accomplished with close tolerances and small radii, thus reducing material wastage due to the cut. Further, the surfaces of the cut are clean and sharp. There is neither generation of heat nor deformation of the material. At the same time, the cutting forces are minimal, which reduces the stresses in the equipment and fixtures.