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Five-Axis Programming Maximizes Flexibility of waterjets
Five-axis waterjet cutting applications begin with an idea. And from a sketch, blueprint, CAD print, three-dimensional wire frame model or Catia file export, the idea becomes a physical reality through five-axis programming.
The following case study is a typical example of a start-to-finish five-axis waterjet application. Creating wire frames begins the programming process.
A screen shot shows wire frames produced by Surfcam,
which is used to program five-axis applications at LAI
Companies.
Designing tooling and fixtures
A fixture concept is designed from a print.
CAD wireframe
A CAD wireframe is generated from the print of both the
fixture concept and the part geometry. This is done in the
final cutting orientation.
Rendering CAD model
The top view of the removed material is pictured. The area
removed is to become the final part.
Once the CAD model is created and surfaces built from the wireframe, the model can then be rendered to give a better appearance of the final part.
A screen shot shows an isometric view of the rendered CAD
file.
Creating the CNC toolpath
A CNC toolpath is created.
Surfcam’s five-axis CAD/CAM programming software is directly integrated with a custom CNC post to create a program capable of cutting the workpiece from the CAD geometry.
Programming for the material type
Bronze-aluminum is used to produce the part.
The .58"-thick bronze-aluminum is positioned on the tooling design and ready for waterjet cutting. With the steep cutting angles involved in the complex motion of the machine, the feed rate averages about three inches per minute. The surface finish is about 250 RMS.
Waterjet is ideal for cutting all materials since there is no heat-affected zone from the cutting process, unlike other machining methods such as laser cutting, milling, torch cutting or plasma cutting.
Performing the waterjet cutting
The waterjet is pictured just after it has beam fired on and
started moving towards the material.
The waterjet nozzle used in this application has an inside diameter of .042" and uses 55,000 p.s.i. of water. The water stream is mixed with garnet abrasive from the white plastic tube pictured above. The abrasive enters an area called the mixing chamber, drawn in by the Venturi Effect created by the waterjet’s high-speed vacuum. The mixture of water and abrasive is then forced through a carbide nozzle.
 Cutting heads are positioned above a large metal tank filled with water. The water dissipates and stops the force of the jet within a few feet. It also reduces noise levels created by the high-speed waterjet stream.
The waterjet cuts through the material.
Completing the part
The finished part is pictured with its print.
From print to part, five-axis waterjet cutting is ideal for many applications, including:
Roughing out material before final machining.
Finished parts.
Hole drilling with angles as steep as 25 degrees from surface.
Edge-of-part contouring.
Slot cutting.
Typical surface finish on the application
is 250 RMS.
Waterjet processing produce high-quality surface finishes, especially with thin materials, and can cut titanium up to 15" thick.
Waterjet Services
Five-Axis Machining
Cutting of large and thick materials
Drilling
Milling
Near-net cutting
Screen manufacturing
Slot cutting
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