Waterjet cutting at the automotive industry
Waterjet cutting is becoming increasingly important in the automotive industry as models change more rapidly than ever. When a different vehicle part has to be produced, all the operator must do is change the programming of the waterjet cutting unit. This makes these machines, referred to as cutting boxes, particularly flexible in production lines where various different components are manufactured. The cutting boxes are equipped with one or more robots with pure water or abrasive cutting heads and allow for multidimensional waterjet cutting. The material is often transferred to the cutting box on conveyor belts or sliding tables. While the component on the front part of the sliding table is processed, the material on the rear section is clamped. Many car parts such as roof liners, floor coverings, fittings, door panels and foamed components are cut with pure water. Harder materials such as composites, alloys and other metals are processed in cutting boxes designed for abrasive waterjet cutting.
Comparison of cutting methods
The table below shows a comparison of laser, plasma and waterjet cutting and the respective material and processing characteristics. Each method has certain advantages and disadvantages, depending on the material to be cut.
Comparison of cutting methods
| |
Laser |
Plasma |
Waterjet |
|
Warping / deformation |
yes |
yes |
no |
|
Material hardening |
yes |
yes |
no |
|
Burr formation |
yes |
yes |
minimal |
|
Need for reworking |
yes |
yes |
minimal |
|
Loss of material |
hoch |
yes |
minimal |
|
Tolerances |
0,1 mm |
0,2–0,5 mm |
0,1–0,3 mm |
|
Hazardous vapours |
yes |
yes |
no |
|
Multilayer cutting |
no |
no |
yes |
|
Material thickness |
< 25 mm |
< 30 mm |
> 250 mm |
|
Non.metallic materials |
no |
no |
yes |
|
Multi-head application |
no |
— |
yes |
|
Composites |
no |
no |
yes |
Main advantages of waterjet cutting at the automotive industry:
- Maximum flexibility as regards production processes
- No heat affected zones
- No wastage, extremely narrow cutting gap
- Allows for tolerances of +/- 0.1 mm
- Multidimensional processing
- Fast and easy prototype production
- No need to rework cut edges
- No need for resharpening the tool
- Stress-free cutting
- No damage to the metal structure
- Maximum flexibility as regards production processes
Cutting speeds
|
Abrasive flow rate |
350g/min |
|
Abrasive |
80 Mesh |
|
Quality of cutting edge |
fine - medium |
|
Orifice diameter |
0,25 mm |
|
Focussing tube diameter |
0,76 mm |
|
Pump pressure |
6.200 bar |
|
Material |
Thickness |
Cutting speed |
|
Steel |
20 mm |
50 mm / min |
|
|
|
|
Pump pressure |
4.200 bar |
|
Material |
Thickness |
Cutting speed |
|
Steel |
20 mm |
35 mm / min |
|
Steel |
10 mm |
120 mm / min |
|
Steel |
5 mm |
200 mm / min |
|
Titanium |
20 mm |
30 mm / min |
|
Titanium |
10 mm |
90 mm / min |
|
Titanium |
5 mm |
140 mm / min |
|
Aluminium |
20 mm |
75 mm / min |
|
Aluminium |
10 mm |
200 mm / min |
|
Aluminium |
5 mm |
350 mm / min |
KMT products for waterjet cutting at the automotive industry
High pressure pumps
KMT Waterjet Systems offers a range of high pressure pumps that cater for all applications. They cover everything from maximum cutting waterjet pressures of up to 6200 bar to maximum volumetric flows of more than 15 l/min and simultaneous operation of a large number of cutting heads.
- STREAMLINE 60/125 PRO – waterjet cutting with 6200 bar
- STREAMLINE SL-V 15-100
- STREAMLINE SL-V 30/50 Classic
- STREAMLINE SL-V 150/200
Cutting heads for abrasive and pure water cutting:
- ACTIVE AUTOLINE PRO – abrasive cutting head for 6200 bar
- ACTIVE IDE PRO – abrasive waterjet cutting head for 6200 bar
- AQUALINE PRO – pure water cutting head for 6.200 bar
- ACTIVE AUTOLINE II – modular abrasive waterjet cutting head for 4100 bar
- ACTIVE IDE II – compact abrasive waterjet cutting head for 4100 bar
- AQUALINE – reliable pure water cutting head
Abrasive systems for abrasive waterjet cutting
- AMS III – abrasive management system consisting of an ABRALINE III abrasive bulk transfer system, a FEEDLINE IV metering system and ACTIVE AUTOLINE II or ACTIVE IDE II cutting heads
- ABRALINE III – abrasive bulk transfer system
- FEEDLINE IV – abrasive metering system
About KMT Waterjet Systems
KMT Waterjet Systems is a leading multinational manufacturer of waterjet cutting systems. The company develops complete solutions for a wide range of industries and applications. Since 1971 the company has been dedicated to long-term customer relationships. Continuous investment in innovation has made KMT Waterjet Systems the market leader in the waterjet cutting industry. High pressure pumps, cutting heads, abrasive systems, high pressure tubes, original spare parts and a global service network are among the key products and services of the company.