If you’re in an industry using water jet cutting machines you know how important proper machine maintenance is. You know that up-time is crucial to productivity and profitability and how devastating downtime can be. This is especially true with water jet cutters using garnet abrasives.
Using abrasives with your water jet cutter adds to the complexity of your system and thus increases your risk for a breakdown and the subsequent downtime. Clogs are one of the most common causes of downtime for water jet cutters using abrasives. However, with proper precautions and maintenance, you can significantly reduce your chances of an abrasive clog in your cutter – keeping your machine cutting longer between regular maintenance intervals. Here are 9 things you can do to prevent abrasive clogs:
Take the time to understand how to choose the right garnet type for your specific cutting and buy your garnet from a reputable source. Make sure they are high quality products before dumping them in your cutter’s hopper.
Humidity is your enemy! Don’t allow your abrasives to be exposed to high humidity for extended periods of time. A high moisture content in your abrasive will restrict flow and make it harder for your machines feeding system to deliver a consistent stream to the cutting head. Make sure you always store your garnet abrasives in a cool dry place when not in use. If your garnet does come in contact with water, allow the abrasives to dry completely before using or simply dispose of it properly.
The orifice and nozzle combination work together and will dictate actual water pressure and flow to the cutting head, which in turn dictates the cutting rates and cut quality your water jet system produces. Similar to orifices, nozzles are rated by the material quality and process used to manufacture them, their I.D. and by their length. A larger ID allows for greater water and abrasive flow and generally provides for a faster cut. A general rule of thumb is getting an ID that is three times larger than the orifice ID. When the proper combination of water flow, water pressure, orifice size and nozzle is not achieved, clogs can occur. Additionally, match the timing between the delivery of the water stream and the abrasive stream. Keeping the abrasive preload light, especially when piercing, improves the cutting. Talk to your manufacturer to make sure you have the correct orifice/nozzle combination before cutting.
Nozzles will tend to wear in an hourglass shape and the larger opening at the top may produce “packing”. Monitor operating time on orifices and nozzles and replace them as soon as you see cut accuracy and finish deteriorating.
Garnet is abrasive by definition and over time all parts that come in contact with it will wear. Check the abrasive feed line from the bulk hopper regularly to confirm enough flow is being delivered to the metering hopper and change it out at scheduled maintenance intervals. Over time excessive wear or a buildup of static electricity, especially in arid regions, may be generated and inhibit flow. Replace abrasive feed tubing, abrasive inlets and other parts that come into contact with the abrasive at regular scheduled intervals and you’ll reduce or prevent longer downtime in the future.
It goes without saying but knowing your machine’s operating manual inside and out can prevent a lot of issues during cutting. Your manual will detail recommended maintenance intervals and specify required parts and components. Post daily routine maintenance at the workstation to remind operators. Monitor cut hours on wear parts. Schedule preventive maintenance before your system goes down to ensure there is minimal disruption to production time.
Visit Jet Edge’s MyEquipment page to learn how you can have your manuals posted online and linked to our E-commerce store so you never have to guess again what parts you need for your system. Take the time to know your individual machine’s manual and you will be rewarded with more up-time.
Operating water jet cutters is no easy task – especially when you add abrasives into the mix. Jet Edge offers a host of on-line resources, including blogs on best practice and maintenance videos to execute service. Our Technical Service Team is also there to help you with your water jetting needs and offers scheduled factory training classes. And if you need a little more Application Help, just let us know.
Since 1984, Jet Edge has been designing and manufacturing Ultra-High-Pressure Water jet technology that doesn't back down. Our systems are used around the world in a broad range of industries from the world's leading airlines, to automotive, aerospace and industrial manufacturers, and machine job shops.
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