Thermal And Non-Thermal Cutting—ESAB Cutting Systems

Modern Machine Shop, March, 2001 by Elizabeth M. Gruber

The company will display its new cutting system featuring thermal and non-thermal cutting processes combined on a single carriage. The machine to be exhibited will be a low-rail model of its Hydrocut waterjet cutting system, equipped with one waterjet cutting head, one PT-15 plasma cutting head, a plasma marker and a laser pointer. The combination of waterjet and plasma allows the machine to make intricate cuts in a part's internal geometry with waterjet and high speed perimeter cuts with plasma. This increases productivity and throughput and greatly reduces cutting costs.

The gantry-style waterjet cutting system incorporates the design and construction features associated with the company's gantry technology, including a sturdy box-beam design; welded, stress-relieved components; and precision-machined contact surfaces for reliable operation. A planetary drive system powered by AC brushless motors provides accurate motion and positioning, with accuracy within [ or -] 0.007" and repeatability within [ or -] 0.003" Cutting speeds range from 0.01 to 750 ipm. The Low Rail style accommodates wide and/or long material sizes. Models range from 8 to 20 ft. in width and up to 75 ft. in length. The floor-mounted rail system provides unobstructed access to the cutting table.

Hydrocut features a waterjet cutting head rated for up to 60,000 psi (4,1 37 bars), with orifice sizes ranging from 0.003" to 0.022" (0.0076 mm to 0.56 mm) and nozzle sizes from 0.020" to 0.065" (0.518 mm to 1.65 mm) interior diameter. This flexibility allows Hydrocut to handle everything from small, intricate cuts to thick cuts requiring higher abrasive and water flow rates. The office and long-life nozzle are designed to maintain a consistent tool center point for the cutting stream. The abrasive cutting nozzle provides maximum cutting speeds with reduced operating costs and simple maintenance, the company says. The pre-aligned cartridge body, orifice and focusing tube produce a sharp and coherent water abrasive stream that cuts faster than other nozzles while consuming less abrasive. The pre-aligned components require no tools for installation, are easily installed in seconds and maintain proper centering when replaced.

The waterjet system features an ultra high pressure intensity pump with continuous output pressure up to 55,000 psi. The pumps provide flow rates as high as 2.0 gpm to accommodate cutting orifices as large as 0.022" (0.56 mm). The axial piston, and variable displacement pumps are available in 30-200 hp. All incorporate pressure compensation features to deliver a smooth, non-pulsating flow over the complete UHP range. Pumps are constructed on an all-steel welded framework with sound insulated for quiet operation. High efficiency, totally enclosed, fan cooled (TEFC) electric motors ensure peak efficiency and long service life.

The versatility of the system is greatly enhanced with the addition of plasma cutting and marking capabilities. Plasma systems provide superior cut quality and durability, and the addition of plasma on the same carriage with the waterjet allows external cuts to be made at increased speed, thereby reducing the part cost. Numerous plasma system configurations are available. The PT 15XLS featured at the show allows cutting from 100 amps up to 1,000 amps for use on ferrous and non-ferrous metals.