Avoiding Secondary Finishing During Welding Process

Weld preparation on exotic or thick materials is usually a time-consuming and difficult process. Weld preparation on angular contours or arcs is even more of a capital and labor intensive procedure. Normally, a secondary operation, e.g. machining or grinding, is carried out to eliminate the heat affected zone (HAZ) and/or slag before welding for the purpose of producing prep angles using thermal cutting processes.

Jet Edge EDGE X-5 5-Axis Waterjet System

The material handling time needed for each of these operations not only impacts the production cost, but also eventually reduces the profit and efficiency and increases the process turnaround time. All of these problems can be overcome by adding the Jet Edge EDGE X-5 5-axis waterjet system, which produces +/- 50° bevels in different configurations (Figure 1) on almost any geometry.

Bevel profiles

Figure 1. Bevel profiles

The waterjet cut does not produce HAZ or slag as it is a “cold” supersonic grinding method, and produces a completely prepped and finished part in a single operation. This cold cutting method prevents the production of recast layer, micro- cracking, or any other changes in the material characteristics. This method also makes OSHA compliance easier, as it does not produce any smoke or fumes, not even the chromium smoke from stainless steel.

The high tolerances of the finished part enable performing consistent and repeatable fitting operations, eventually saving additional labor costs (Figure 2).

A fully prepped, finished part obtained in one operation.

Figure 2. A fully prepped, finished part obtained in one operation.

Thicker materials can be processed using a single 12” Z-axis travel in one setup, significantly reducing production cost and time. The EDGE X-5 5-axis waterjet system is incorporated with contact surface sensing and laser material mapping features, enabling an uneven material to be accommodated and ensuring that the material is relieved during the cutting process. The bevel features can be added in a fast and simple manner using the IGEMS CAD/CAM software.

Other Functions of Jet Edge EDGE X-5 5-Axis Waterjet System

Apart from beveling, the taper angle control (TAC) function of the EDGE X-5 5-axis waterjet system can be utilized to produce nearly taper-free cuts. The extensive tech table included in the IGEMS CAD/CAM software allows the EDGE X-5 5-axis waterjet system to compensate for the inherent taper caused during the waterjet cutting process, enabling end users to select any edge quality to produce taper-free parts. As the tech table is user-definable, the programmer/operator can change the TAC data characteristics for any material, in addition to editing and creating novel materials according to individual requirements. The novel IGEMS TubeCut module provides the ability to cut features into tubes/pipes, allowing the EDGE X-5 5-axis waterjet system to be used as a powerful tool in any fabrication facility.

Advantages

Similar to several other Jet Edge waterjet motion systems, the EDGE X-5 5-axis waterjet system has a completely supported, rigid gantry design (Figure 3).

The EDGE X-5 5-axis waterjet system.

Figure 3. The EDGE X-5 5-axis waterjet system.

Completely driven by ball screws, the EDGE X-5 includes Rexroth AC servo motors and drives, and high-quality motion components which are controlled using a robust industrial PC that can withstand a highly demanding production schedule. The system includes a standard handheld pendant that enables the operator to control the system from any point around the machine. The filtered blowers and sheet metal enclosures, equipped on each axis, prevent environmental contaminants from reaching the paths or ball screws, ensuring high reliability, longer working life, and lower cost of the EDGE X-5 5-axis waterjet system.

Conclusion

The Jet Edge EDGE X-5 5-axis waterjet system enables precise cutting of taper-free parts. As a complement to the EDGE X-5 5-axis waterjet system, Jet Edge also provide a complete line of UHP intensifier pumps with a horsepower range of 30 to 200, 60,000 or 75,000 PSI. The patented seal design and the tie-rod intensifier construction ensure maximum up time and minimal maintenance.

This information has been sourced, reviewed and adapted from materials provided by Jet Edge, Inc.

For more information on this source, please visit Jet Edge, Inc.

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