Filling the gap between EDM and micro-laser

Waterjet cutting is a common method for processing parts in high density materials such as aluminium, stainless steel, titanium and carbon composites. The FAWJ cutting process bridges the gap between micro-laser and EDM cutting and brings waterjet cutting into the field of micro-part processing.

To enable such levels of precision you need two things. Firstly, a cutting head and cutting process for FAWJ cutting, and secondly a machine built for high accuracy. The NCM 10 Micro from Water Jet Sweden fulfils both of these requirements, according to the company.

The micro waterjet cutting head developed by Water Jet Sweden in 2008 is a high precision cutting tool producing one of the most precise abrasive waterjets in the world. The specialised cutting head enables an abrasive jet diameter down to 0.2mm. The FAWJ cutting process requires very fine abrasives of 230-240 mesh and a special CNC controlled dosage abrasive feeder.

To reach the levels of accuracy required in micro part manufacturing, the NCM 10 waterjet has a number of innovative design features to create a rigid table that withstands temperature fluctuations

These include: a mineral cast Bearlit table frame – a table frame made of a composite material with exceptional stiffness that withstands vibrations and temperature fluctuations. The frame is integrated into the machine’s construction and motion system as a complete unit; a rubber suspended stainless steel water catcher – the free-standing catcher solution prevents vibrations and temperature variations from influencing the cutting process. Stainless steel makes it maintenance free; lastly a Renishaw Invar Scale in X and Y encoder – with a Renishaw Absolute Linear Encoder fitted in both X- and Y- axes users have a micrometre scale with an extremely low expansion coefficient and ultra-high resolution.

The palletised cutting table makes it easy to install fixtures and presses for different types of machining. Maximum table size is 1 x 1m which covers most cutting applications. The cutting table is fixed into the table frame to enable ultra-high precision cutting.

“There are many suppliers who state that they offer micro-cutting machines, but not many can offer a true micro-part cutting tool with 0.2mm incision combined with ±0.008 accuracy,” says Tony Rydh, co-founder and CTO at Water Jet Sweden.

Water Jet Sweden has made a performance comparison between (FAWJ) micro waterjet cutting and EDM.

When cutting tempered tool steel 15mm thick the NCM 10 was able to cut at a maximum speed of 11mm/minute and a minimum speed of 4mm/minute. Its cutting accuracy was 0.02mm. Manufacturing time for the cutting project was one hour 30 minutes and the total cost was €180.

For the EDM machine cutting speed was around 1-2mm/minute, accuracy was 0.001mm. Manufacturing time was just under eight hours and the cost was €480.

Back in 1993, Water Jet Sweden machines were built in a private garage. Today the company serves customers in more than 40 countries. The company’s home town of Ronneby in Southern Sweden has become an R&D cluster of global renown, where the scientific establishment, the waterjet industry and the business community collaborate to develop the waterjet cutting technology of tomorrow.

The company says its ultimate aim is to offer customers value, and the benefits of its machines and service are highly measurable in terms of time, money, product quality and sustainability.

Water Jet Sweden https://waterjetsweden.co.uk