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Industrial Engineering Technology

What Does the Future Hold for Water Jet Machine Manufacturers?

According to water jet machine manufacturers, the early generation of waterjets can cut through soft materials very easily. However, they are not as effective when working on harder materials, and that includes metals. Water jet cutting machines started having this capability only after the idea of adding abrasive material to the cutting nozzle was thought of.

The technology of adding abrasive material to the waterjet cutting machine nozzle was pioneered by Leslie Tirrell and Elmo Smith in the 1930s. Back then, the service life of an abrasive waterjet nozzle was too short. Hence, they were obviously not viable back then. For that reason, mass producing it was not a practical idea and was thus shelved for quite some time.

The plan for mass production was only relaunched only after several material innovations came to surface by virtue of mixing tubes. The production of the commercially acceptable nozzle was initiated by Boride Corporation.

By fusing high-pressure pump and abrasive waterjet nozzle, water jet cutting machines are now made better than ever. They can now handle cutting through a wide spectrum of materials, including titanium, glass, stone and even hardened tool steel.

Nowadays, water jet cutting is considered by industry experts and insiders as among the leading cutting technologies we have in this modern time and age. The acceptance and level of popularity of the waterjet manufacturers and business sectors for this method of cutting have finally qualified it as the go-to choice for many.

While this technology has undergone several innovations and improvements in the past, the silver lining question here is where is it leading us to?

Faster

Compared to how it was back then when waterjet cutting machines were first introduced to the world, it has become a lot faster. This was after it was made to deliver higher water pressure via the machine’s cutting head.

Water pressure through the cutting head can reach up to 87, 00 PSI. This is water delivered to at least 4 times the sound speed. Over time, it is anticipated that this speed we now have will still go further and faster.

Nonetheless, it should be noted that speed gains may not happen through water pressure anymore. Instead, further improvements will focus more on design and software upgrades.

Thicker

Right this very moment, water jet cutting is already leading the way. It is capable of cutting through depths 10 times more than what a laser cutter does.

By virtue of increased water pressure, it would still be possible for it to cut deeper still. In a few years, perhaps we can make a seamless cut on metal that is half a meter’s depth.

Cutting Complex Parts

By far this can be considered as the biggest milestone in recent years. Water jets can now cut parts beyond the basic 2-dimensional cut we see.

XD cutting is now made possible through water jet cutters. It is a cutting head, capable of moving on multiple axes. This also signifies that it can cut complex 3-dimensional parts and that it can be carried in just one, singular strike. It is contrary to what you do in secondary cuts, which are time-consuming and costly, too.

The XD cutting technology is usually employed by the likes of formula one teams and Boeing. These industries require complex metal parts for their machinery, and they need to be done in the most accurate way possible.

There is more coming to this area, and it is anticipated that it will grow even further. Water jet cutting machines that are made capable of cutting more complex parts, more detailed and at a quicker pace.

Besides, industry experts are agreeing with each other that there will be a greater level of awareness about this technology. Business organizations will see this technology can save them both time and money on their metal cutting requirements.

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Industrial Engineering

What are the Common Telltale Symptoms of Fuel Contamination in Silvan Tanks?

Much like any other containment system for high-value liquids, silvan tanks, without proper care and maintenance, are prone to fuel contamination, too. Liquid fuel contamination — we define this as a presence of foreign matter that should not be there. 

This issue accounts for a wide array of the fuel-related concerns we have today. If this occurs, fuel quality is likely to degrade soon enough and produce inappropriate things, for example asphaltenes. Under pretty normal conditions, they are not supposed to be there but are now contaminating your liquid fuel.  

With the burgeoning of wrong information hounding this issue on contamination of liquid fuel, we figured that it might be a good idea to come up with a “down and dirty” compilation of the most common symptoms that can pave the way for it.

In resolving any kind of fuel-related problem, the first two critical steps would be to recognize what the problem really is and to correctly identify its underlying causes. After this, the drafting of a proper solution can be carried out and eventually implemented.  

While these “symptoms” may well indicate the presence of something inappropriate in your high-value liquid, when it is about knowing exactly the underlying reasons behind a particular symptom, there may be possible multiple root causes.  

White, Black or Blue Smoke 

Smoke is usually comprised of petroleum particles that have remained uncombusted. Smoke is not likely to become a byproduct of a properly-functioning engine that can efficiently and completely burn liquid fuel. 

Take smoke as a good indicator. Its presence may well indicate that your fuel may contain something that is not supposed to be there, provided of course that your engine is in proper working order. 

To identify exactly what that is may necessitate you to do more than just a little detective work. But the usual culprits are the heavier petroleum compounds. They may be fuel heavy ends, asphaltenes, sludge or even lube oil — normally they don’t burn easily and cleanly the way fresh fuel will.  

Off-Color Appearance or “Smelly” Fuel in your Silvan Tanks

You know that you have fresh gasoline or diesel by their sheer appearance, clear and bright. Another thing is that they also have this characteristic “solvent” smell in them. If the fuel is harboring entrained water, it is likely going to give it a cloudy appearance. 

The darkened appearance of your liquid fuel indicates that it is likely unstable already. Take it as a clue that it might be in the process of producing heavy ends and asphaltenes. Or if your liquid fuel is giving off an odd smell, it is an indication of microbes in the liquid fuel. This usually occurs when the tank does have in it significant amounts of water. 

fuel tanks contaminant

Engine Shuts Down or Runs Rough 

If your engine would eventually shut down on its own, without any apparent reason behind it, or would run rough like it never did before, take it as an indication that there might be some kind of foreign matter in your tank. 

Since we are dealing here with contaminants, we are going to preclude an issue such as the diesel fuel’s inadequate cetane rating. But in terms of contaminants, you would not want to take water or heavy end substances out of the equation, most especially in a marine or gas engine. 

It is also a good practice to keep an eye on your filter because there is a good chance that contaminants have found their way in there and is restricting the flow of your filter. If that happens, your engine’s performance will get compromised because it will not run properly. 

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Industrial Engineering

How to Properly Maintain Your CNC Plasma Kits Australia Machines?

One may think or qualify maintenance of CNC plasma kits Australia as some kind of a boring chore when compared to the aspects of running and keeping a successful machine fabrication shop. Proper maintenance or the upkeep for these machines is of prime importance not only because of the repair costs but more importantly due to the possibility of losing great amounts of profit if their equipment will be shut for some needed some repairs.

Preventive Maintenance Plan

If you want your CNC plasma kits Australian tools running smoothly and will help in keeping your business raking in more profits, it is paramount to have a preventive maintenance plan in place. This will be comprised of routine check-ups for your pieces of equipment to help in boosting up their efficiencies. It will also help increase their uptimes and in doing so will significantly enhance your expectable profit margins.

Are you not convinced yet? Here is something worth pondering on. CNC cutting machines, in the sheer absence of a good maintenance plan, are likely to experience unplanned breakdowns and this occurring may cost you 5 times more compared to annual PMPs. Between the wasted, unproductive hours and expedited part shipment, a solid PMP program in place will win for your business affordable machine maintenance.

Daily Care Routine for Your CNC Cutting Machines

  • Set a convenient time to inspect your hydraulic pressure and see to it that it is set at 4.5 MPa. 
  • Verify that your machine’s hydraulic fluids are on the right operating level. 
  • Verify if your chuck pressure is set to the right operating pressure as per manufacturer instruction.
  • See to it that your lube level is at the correct operating level and to replenish it as necessary.  
  • CNC cutting machines equipped with its cooling system must be set at the right operating level all the time.  
  • Make it a habit to clear the chips from the chip pan. 
  • Make it sure that you clean your machine’s window door and light, this way you can see what is inside.

Every week or right after the lapse of 40 hours or so, make it sure to take off your CNC control cabinet. Regular cleaning of this area is paramount to have proper ventilation and ease out cooling.  

Every 3 Months

After every 500 hours of use, make sure that you check out the chip conveyor chain and grease it as necessary. Also, don’t skimp on checking and cleaning out the filters on the coolant tank.

Every 6 Months

After every six months, doing the math we’ll see this is equivalent to 1000 hours, after the lapse of this period you may need to reach out to your local distributor and have them perform the following preventive maintenance measures on your CNC cutting machines:

  • Clean the coolant tank and clear it from chips, sludge, and oil. 
  • Dismantle the chuck and jaws from your CNC cutting tool to have it cleaned. 
  • Drain the hydraulic tank and change your hydraulic oil with a new one. 
  • Clean the radiator and see to it that your machine radiator fins are straight. 
  • Drain and clean your lubrication unit before you put on fresh lube to it. 
  • Have your machine leveling checked and make proper adjustments as necessary.  
  • Check also your wipers and inspect for any damage, replacing them as necessary.  
Plasmacam Australia

Once a Year

After every 2,000 hours of usage of CNC plasmacam Australia machines, which is roughly after a year, once every year reach out to your local distributor and have him inspect the following:

  • Check out the headstock and look for any tapers
  • Check out your machine spindles and inspect for radial or end play.
  • Inspect your chuck cylinder and check it for run out. 
  • Check your tailstock for any taper presence.
  • Have your machine’s inclination and turret parallelism inspected. 

Then finally, make it sure that your distributor will perform a backlash program. By this measure, they’d be able to see if the backlash in the X and Z axis are in proper order. Otherwise, make proper adjustments as necessary.

Categories
Industrial Engineering Technology

How is a Water Jet Cutting Machine Different from Laser Cutting?

It is surprising to know that many people today are still unaware of how efficient water jet cutting machines are. The working idea behind this popular material cutting method was inspired by how a waterfall wears away rock formations at the bottom of a deep ravine. Only that it is done in warp speeds, and executed with greater emphasis on precision.

The Power of Water Jet Cutting Machine

To further intensify the cutting power of a waterjet cutter, the pressurized water used for these cutting machines can be mixed with abrasive particles. Typically used for this purpose are aluminum oxide and garnets.

As for the cutting force of water jet cutting machine, it can reach a maximum power of 60,000 psi. This explains the reason why this material cutting method is most recommended and preferred for projects that involve cutting of thicker material objects where the use of laser cutting method may not be very feasible at all, or would just run the risk of giving poor quality cut.

Some of the most common reasons why a significant number of metal fabrication centers in the country are shifting or patronizing the use of waterjet machines are due to the following: 

It can be used when working on thicker materials, including patterns that come with large tolerances.

They are trying to veer away from heat interference due to laser transferring its heat to the materials being cut. At high risk here are patterns that are so close to each other.

Waterjet cutting allows your metals to lay flat throughout the entire cutting process. In the laser cutting method, there are instances that you need to know how to put them at the right level.

Their team is involved or deals with an array of different materials. Waterjets earned a good reputation in cutting through stone, ceramic, steel, reflective metals, and many others.  

Laser Cutting

Laser cutting machines are in high demand these days, even from the very first day they were introduced to the market and we attribute this to their high level of precision. They also gained wide acceptance among various industries because they cut your materials fast.

But if there is one major setback you can complain about this method of cutting, it is the fact that you are limited to cutting only ⅝ of thickness. Beyond this level of thickness, it is hard to maintain an exceptional quality of cut.

Today’s software applications allow you to send a CAD file to the laser computer. After which you can begin cutting materials for your project within seconds. Many fabrication shops in the country are employing this method to help address their prototyping needs.

Laser cutting machines come with a stackable material tower which makes them ideal for big production runs. Many companies execute long, overnight cutting runs. They also leave these cutting machines unattended. 

Major Differences of Water Jet Cutting Machine and Laser Cutter Devices

Laser Cutting VS Water Jet

Infrared Light and gas laserEnergy and SourceWater and high-pressure pump
8 x (4 -20’) x 6.5’Standard Table Size8 x (4-13’) x 6.5’
Sheet MetalCommon Cut MaterialsStone, ceramics, thick metal
0.31” to 0.4”0.06”Economical ThicknessMinimum Hole Size0.250” to 2”0.02”
0.002”Tolerance0.008