Characteristics and Application of Numerical Control Ultra High Pressure Water Jet Cutting Technology

The characteristics and application of machine tool and hydraulic bookmark0 numerical control ultra-high pressure water jet cutting technology Chen Guangming (Nanjing Agricultural University, Nanjing 210031, China) New technology and new technology. Ultra-high pressure water jet cutting is an unconventional cold cutting method that has the advantage of traditional cutting methods. This paper discusses the basic working principle of numerical control ultra-high pressure water jet cutting machine, the processing form of water jet cutting and the composition of water jet cutting machine. It describes the processing characteristics and application fields of numerical control ultra-high pressure water jet cutting machine and the ultra-high pressure water jet. The development trend of cutting technology has been prospected.

Foreword In recent decades, with the continuous discovery of science and technology, people have given the droplets a much larger blow energy than the free fall motion, so that the long dripping water can be completed in an instant, which is the water jet.

In order to increase efficiency, the water is pressurized and sprayed into nozzles of smaller diameter to form a bundle of high-speed, continuous or intermittent water jets, which is a high-pressure water jet. Waterjet processing (WateretCut ting), also known as water jet processing, is the use of high-pressure high-speed water flow impact on the workpiece to remove the material, commonly known as "waterjet processing" is the use of ultra-high pressure (up to several hundred MPa) water jet for various The material is processed by cutting, perforating and removing the surface material of the workpiece.

Water jet technology enables a variety of processes such as cutting, degumming, cleaning, drilling, trimming, grooving, and removal of workpiece skin materials. The development of industry and the emergence of new materials have placed new demands on the processing. For example, some special materials are used in the aerospace manufacturing industry, such as titanium alloys, carbon fiber composites, reinforced plastic glass, etc., which are difficult to cut by other methods or have processing quality problems. Unlike laser cutting, plasma cutting and wire EDM, high-pressure water jet cutting is an ideal or unique processing method for aerospace materials that are difficult to cut by other methods due to their unique advantages. High-pressure water jet cutting is an unconventional cold cutting method that has the advantage of traditional cutting methods.

This paper will introduce the ultra-high pressure water jet cutting technology used in the industry, and specifically describe the processing characteristics and development direction of the ultra-high pressure water jet cutting machine.

1Ultra high pressure water jet cutting machine working principle The basic working principle of high pressure water jet processing technology is to use the liquid pressurization principle to convert the mechanical energy of the power source (motor) into a specific energy transfer device (supercharger or high pressure pump). The pressure energy of water, the water with great pressure energy, after passing through the small orifice nozzle, converts the pressure energy into kinetic energy, thus forming a high-speed water jet, which is sprayed onto the surface of the workpiece. When the water jet impacts the workpiece being cut, the kinetic energy is changed again. The pressure energy acting on the material, if the pressure can exceed the breaking strength of the material, the material can be cut to achieve the purpose of processing the material. High pressure water jets are therefore often referred to as high speed water jets.

The specific working principle of the cutting machine is to filter the ordinary water, then pressurize it step by step through an ultra-high pressure supercharger, pressurize the water flow to 200~40CMPa and then pass a diameter of CNC super-high pressure water jet 0.1~0.3mm. The nozzle cutting machine schematic (generally made of sapphire) forms a water jet with a jet velocity of up to 1 (approximately 3 times the speed of sound) and a kinetic energy. This water jet is like a cutting tool. Under the control of the numerical control system, the workpiece to be processed is cut and formed. The principle of numerically controlled ultra-high pressure water jet cutting machine is shown. It can be known that the abrasive is first sent to the mixer through the abrasive supply device, and the water of the tank passes through the ultra-high pressure water jet generator to become high-pressure water, and the abrasive is mixed with the high-pressure water in the mixer. Then, the nozzle of the water jet cutting head device is sprayed toward the cutting workpiece at a high speed of several hundred meters per second. At the same time, under the control of the numerical control system, the waterjet cutting head device performs plane movement according to the trajectory required by the user's machining program, and finally cuts out the workpiece required by the user. At present, the water jet cutting machine adopts the industrial computer as the hardware platform and the operating system of Window98 as the software platform. The system has automatic programming, processing track graphic simulation, human-machine interface friendly and network communication functions.

2 water jet cutting form and water jet cutting machine configuration 1 water jet cutting form water jet cutting form from the water quality, there are pure water cutting and abrasive cutting; from the pressure method, there is hydraulic pressure and Mechanical pressurization; from the mechanical structure of the machine tool, there are gantry structure and cantilever structure; from the drive mode, there are stepper motor drive and AC servo motor drive.

From the water quality, there are two forms of ultra-high pressure water jet cutting used in the industry. One is pure water cutting, which can easily cut soft materials of any shape. The slit is 0.1~1.1mm (such as food processing). When the water pressure is above 10 (MPa), soft materials such as food, sponge, rubber, leather, fiber, plastic, paper and textile can be cut; the second is abrasive (usually 60~100 mesh quartz sand and alumina) Etc.) cutting, the slit is 0.8~1.8mm (such as steel plate cutting). The addition of abrasive makes the water jet have the characteristics of the saw blade, increasing its cutting force, the force of the water jet is greatly enhanced, and the abrasive water jet cutting can be almost Cut any hard material such as metal, composite, stone, ceramic, glass, etc.

The gantry structure and cantilever structure of the CNC shaft, this structure is mostly used for cutting plates; the robot structure of 5-6 CNC axes, which is mostly used for cutting automotive interior parts and car linings.

The simplest ultra-high pressure water cutting machine has 2 CNC axes, CNC controlled X-axis CNC movement, and can realize CAD / CAM direct conversion, truly free keyboard input, no picture processing, as long as it is drawn in CAD Complex curves can be cut directly.

2.2 Water jet '/flow cutting machine tool composition A numerical control ultra-high pressure water jet cutting machine consists of ultra-high pressure water jet generator system, waterjet cutting head device, CNC cutting platform, numerical control system and its auxiliary devices. The high pressure part is the heart of the water jet cutting machine, and the numerical control part is the brain of the water jet cutting machine.

It is the structure diagram of the gantry type numerical control ultra-high pressure water jet cutting machine. Among them, the CNC cutting platform adopts the unique gantry double-drive gantry type CNC ultra-high pressure water jet cutting machine structure. The high-speed operation state will not produce vibration and deformation. The machine tool adopts AC servo motor, high-precision ball screw and rolling guide to ensure High-precision machining of parts; high-performance water-cutting special CNC system (as shown) is not only fully functional, but also realizes three-axis linkage control, with powerful network functions, menu-based operation is simple and easy to learn, and the equipment is extremely reliable. Sex, control the machine and high-pressure pump in the PC environment of PC; the perfect protection system can effectively waterproof and sand control, make the machine durable; centralized automatic lubrication system makes the maintenance of the equipment simple and convenient.

CNC water jet cutting special CNC system 3 Ultra-high pressure water jet cutting machine processing characteristics Water jet cutting Compared with traditional cutting methods such as laser cutting, plasma cutting, wire cutting, etc., it has the following processing characteristics: the versatility of the meter, good 1" even in the narrow gap material. The slit narrow e (0eS758mm) wS bucketbookmark3 has excellent cutting quality and high processing quality. Water jet cutting is an advanced "cold cutting" processing technology. When the waterjet cutting process is performed, no heat is generated, and there is no heat influence on the workpiece material, so the workpiece does not generate heat affected zone and thermal deformation, and does not cause structural changes or deterioration of the material, which is especially suitable for processing heat sensitive materials such as titanium alloy. It is advantageous; there is no crack when cutting water, it can be used for cutting. Generally speaking, the cut of pure water is 0.1 ~ 1.1mm and the cut is between 0.8 ~ 1.8mm, with the inner hole of sand nozzle The larger the diameter, the larger the incision. The cutting quality is good, almost no flashing, burr, vertical cutting surface, smooth and flat cutting, no cracks, no scum; small cutting force, the lateral and longitudinal forces generated by the water jet on the workpiece are extremely small, The material does not produce direct surface pressure, there is almost no mechanical stress and strain, the workpiece deformation is small, and the machining accuracy is high.

high productivity. Waterjet processing has high cutting speed, high efficiency and low processing cost. Because high-pressure water can generate very high energy after passing through small-diameter nozzles, high-pressure water jet technology is very efficient and can be concentrated in a small area. energy of.

Wide adaptability of workpiece materials. Because ultra-high pressure water jet cutting is almost "invincible" with almost no material and cutting size restrictions, it is known as the "universal cutting machine." It can be used for cutting various soft and hard materials, conductive and non-conductive materials, metal and non-metal materials, plastic and brittle materials, composite materials, etc. It can easily cut steel plates or hard marble, granite, etc. Materials that are difficult to cut by other methods, such as titanium alloys and various composite materials, are highly desirable or unique processing methods.

Highly flexible. It can cut any contour, and the cutting point and the end point can be selected at any point on the surface of the workpiece. It can be used for all-round cutting. It can be cut from any point without any limitation of cutting direction. It can cut out any complicated graphics and can complete various kinds. Shaped machining, including a variety of shapes, angles or slopes, and the editing of the program is also easy.

The working environment is good and the operation is safe and reliable. The waterjet is safe. The distance between the waterjet nozzle and the material to be cut is 2~3mm. It is difficult for ordinary people to reach below. Because the working medium is water, there is no dust, no environmental pollution, no noise, no pollution during the cutting process, clean and no fly dust during the cutting process, and it has the functions of cooling, dust elimination and lubrication, which can reduce a large amount of dust. Environmental pollution will not harm human health; improve the working environment, clean operating environment, meet environmental protection requirements, improve the safety of operators; no sparks and toxic gases will be generated during cutting, which can effectively avoid fires. Due to the cooling effect of water, the workpiece temperature is low, which is very suitable for the processing of flammable and explosive materials such as wood and paper, which is very important for safety engineering, especially coal mine production.

Processing costs are low. No need for secondary processing such as edging, no need for coolant, saving time and reducing manufacturing costs; processing “tool” is high-speed high-pressure water flow, water knife is not worn, it will not become dull during processing, and tool preparation is reduced , sharpening time, etc., while the cutting quality is good and stable, the process consistency is good, and the efficiency is high. In addition, the waste generated by the waterjet is usually more valuable because it is a whole piece rather than debris and can be used again.

It has the characteristics of green manufacturing process. Cutting water and abrasive sources are sufficient. The working medium of high-pressure water jet is water, which is not only rich and easy to obtain and cheap. People know that water resources are a renewable and non-polluting resource. The development of water energy has a positive effect on promoting national economic development, improving energy consumption structure, and reducing environmental pollution.

Easy to implement automatic control, easy to operate. The working mechanism of the high-pressure water jet has a small nozzle size and convenient movement, and is convenient for numerical control control, and is convenient to operate. All operations can be controlled by software, which is easy to understand and easy to learn, and reduces labor intensity of workers.

In short, the high-pressure water jet technology meets the requirements of the green manufacturing concept. The CNC water jet cutting machine combined with the super-high pressure water jet generator is used as a general-purpose cutting machine for various materials: ceramics. , stone, glass, chemical fiber, composite materials, alloy materials, etc. for any graphic plane cutting. Especially suitable for building decoration stone mosaic, clothing industry (cutting leather, fabric), automotive industry, food processing industry. Such as cutting samples of ultra high pressure water jet cutting machine. Compared with the traditional cutting process, water jet cutting has the characteristics of narrow slit, smooth and straight cut, no heat deformation, edgeless seaming, fast cutting speed, high efficiency, no pollution, safe and convenient operation and low cost.

Cutting sample of ultra-high pressure water jet cutting machine 4 Application field of ultra-high pressure water jet cutting technology Water jet processing technology is applied to cutting, which is a revolution in the field of cutting in a sense. With the maturity of water jet technology and the overcoming of certain limitations, water jet cutting is a perfect complement to other cutting processes and has a wide application prospect.

There are many kinds of materials processed by water jet cutting, mainly non-metal or metal materials which are difficult to process or can not be processed by general cutting methods, especially some new and synthetic materials. At present, ultra-high pressure water jet cutting technology is widely used in ceramics, stone, cement products, paper, food, plastics, cloth, polyurethane, wood, leather, rubber, glass, chemical fiber, metal, hard alloy. , die steel, titanium alloy, tungsten molybdenum cobalt alloy, composite materials (such as metal-based fiber reinforced metal, fiber reinforced rubber, etc.), stainless steel, aluminum alloy, high-wafer cast iron and malleable cast iron, etc. Plane cutting. Because ultra-high pressure water jet cutting is almost “invincible”, it is an ideal or unique processing method for materials that are difficult to cut by other methods, such as titanium alloys and various composite materials. The main application areas of technology i Ultra-high pressure water jet cutting is suitable for almost all industrial fields, such as machine manufacturing, mold manufacturing, metal processing industry, aviation manufacturing, aircraft manufacturing, automotive manufacturing, stone processing and construction, ceramics Industry, light industry, paper industry, rubber industry, textile and leather industry, electronics industry, food industry and other industries. Water jet cutting carbon fiber composites, a variety of hard metal and non-metal materials, or materials with honeycomb structure. Take the automobile manufacturing industry as an example. The processing of automotive interior materials (such as car carpets, instrument panels, canopies, etc.) accounts for 40% of water jet processing. In addition, it is also used in automotive rear frames, wheel covers and insulation materials. Cutting. Due to the development of numerical control technology, water jet cutting is easily controlled automatically by a computer, so that workpieces of various curved shapes can be cut. At present, thousands of water jet automatic cutting production lines have been installed at home and abroad.

High-pressure water jet technology is widely used in bridges, hydropower projects and other departments that use reinforced concrete structures, especially in coal, petroleum, chemical, military, nuclear industries and other sectors with harsh natural conditions and work hazards, which can efficiently operate and greatly reduce workers. Labor intensity, improve the working environment, reduce and prevent the occurrence of dangerous accidents. High-pressure water jet spray dust reduction and cutting concrete structures can play an important role in earthquake rescue and post-disaster reconstruction.

The cutting or breaking of high-pressure water jets of buildings can be cut, opened and broken in various buildings according to people's wishes. Therefore, it can be used to demolish old buildings, repair bridges, excavate trenches for laying cables or gas pipes, break roads, and so on.

Although theoretically ultra-high pressure water cutting can cut any material, it is still somewhat important in application. There are three main uses for ultra-high pressure water cutting: one is to cut non-combustible materials, such as marble, ceramic tiles, glass, cement products, etc., which are materials that cannot be processed by thermal cutting; the second is to cut flammable materials, such as steel plates. Plastics, fabrics, polyurethanes, wood, leather, rubber, etc., can be processed by conventional hot cutting, but it is easy to produce burning areas and burrs, while water cutting does not produce burning areas and burrs, physical and mechanical materials to be cut. The performance does not change, which is also a major advantage of water cutting; the third is the cutting of flammable and explosive materials, such as ammunition and cutting in flammable and explosive environments, which cannot be replaced by other processing methods.

Under normal circumstances, when laser, plasma, flame, wire cutting, sawing, milling and other processing methods can basically meet the processing requirements, it is not suitable to use water cutting. After all, the water cutting operation cost is high, nozzles, diversion sleeves, High-pressure seals, etc. are imported consumables, which are more expensive. But when you feel that the thickness of the laser and plasma can be cut too thin, the resulting burrs are too large, and the heat affected zone is unfavorable, you can consider using water cutting; when you feel the burr of the flame cutting is too large, the roughness If the heat affected zone is too large, you can consider using water cutting when you can cut non-conductive materials. When you feel that the milling method has produced a lot of waste and caused a lot of waste, you can also Consider using water cutting; when you feel that using circular saws and band saws is too slow and you can't make non-linear cuts, you can consider water cutting; when you cut flammable or explosive materials or in a flammable and explosive environment When cutting, you must consider the use of water cutting; when you cut, do not want to produce toxic auxiliary gas, do not need secondary processing, do not want to produce thermal effects or deformation or micro cracks, and want to produce good trimming quality and can cut small holes at the same time When you need to consider water cutting. In short, water cutting is a versatile cutting method, but the use is not optimal in some cases, so make a specific analysis when choosing.

5 Ultra-high pressure water jet cutting technology development trend is obvious, ultra-high pressure water cutting has many advantages, water jet cutting process can cut almost all kinds of materials, but also put forward higher requirements from the technical point of view, such as numerical control technology, water jet pressure , cutting speed (moving speed of the cutting torch), nozzle shape and outlet diameter, and wear resistance of the nozzle material, ultra high pressure sealing problem, ultra high pressure pressure vessel safety problem, ultra high pressure reliability, supercharger design The development of mechanical structure design, abrasive type selection, injection technology, and ultra-high pressure water jet cutting technology are the focus of the industry.

The development trend of ultra-high pressure water jet cutting technology can be summarized as the following aspects: the host design is becoming more and more perfect. For example, the super high pressure and high power of the main engine, the current pressure of the water jet has exceeded 50 (the research and development of the ultra high pressure and high power of the MPa main engine are very active, and the design work pressure is higher, and the more stable high pressure system is the current research. One of the hot spots. For example, there are two high-voltage generators in the high-voltage part of the country. One of the high-voltage generators works, the other high-voltage generator is used alternately, and the two high-voltage generators work alternately to ensure continuous operation of the machine tool. And the protection function makes it safer to operate and easier to maintain; the machine tool has high positioning accuracy, its linear positioning accuracy is 0.076mm, and the repeat positioning accuracy is 0.050mm. The automatic height adjustment system is designed to automatically adjust the cutting head during the cutting process. The distance from the workpiece to ensure excellent cutting quality and prevent the sand tube from being broken; in addition, if it is developed to install multiple cutting heads, a high pressure system is used, and 3-4 nozzles are simultaneously driven to cut simultaneously. Sanding head with automatic sand transport device; height and collision sensor; increased automatic sand removal system and so on.

Cutting process parameters are continually optimized to further increase efficiency, reduce abrasive consumption and reduce energy consumption, such as optimal abrasive usage to save costs. The workpiece material database is stored, and the user can automatically change the processing parameters according to the material type, thickness and processing requirements of the workpiece, and the operator can expand the database by himself.

Choosing, the cutting vine feels too slow, and realizes the development from eT's two-axis control system to five-axis, and i is used for the bookmark4 control system to pursue intelligent and numerical control. It is necessary to further improve the functions of the dedicated water-cutting CNC system and develop intelligent control so that the process parameters can be adaptively adjusted during the machining process. Especially 1 Liu Jinchun. Special processing M. Four edition. Beijing: The machinery industry has 2 Hu Chuanqi. Special processing manual. Beijing: Beijing University of Technology Press, 2001. 3 Sun Daqi 01 advanced system 1 skill (soul £1 (1 3D contour cutting control system. PC-controlled simple programming system with graphic display interface. Cutting path simulation Demonstration, used to check the cutting process, calculate the length of the cutting path, cutting time, and calculate the processing cost.

Further expand the application range of ultra-high pressure water jet cutting processing. The five control axes cut the three-dimensional contour and further expand the range of applications. From two-dimensional cutting and deburring processing to hole machining and three-dimensional profile machining. The water jet processing equipment combined with the robot stands out. The high-pressure water pipe is spirally wound around the robot arm. The robot arm and the wrist can be used to quickly run the nozzle of the water cutting head along a straight line or an arc to achieve the purpose of machining the workpiece in three dimensions.

In the future, it is necessary to increase research in the production of materials, processing technology, assembly processes and so on. Improve the reliability of equipment and the life of parts such as wearing parts, especially the life of key components such as high pressure pumps and nozzles. Since the flow rate of water jet reaches 2 to 3 times the speed of sound, the pressure is up to 50 CMPa or more. Due to the strong pressure, many parts like nozzles, sand pipes, seals, etc. are prone to wear and have a low life, and have to be shut down for adjustment and replacement. The life of the high-pressure pump and the valve body can reach 6000 hours, and the life of the nozzle can reach 2 000 h, but most of them can not reach this index. Therefore, how to improve the performance of materials and adopt a series of anti-wear measures to prolong the life of consumable parts and reduce the cost of water cutting processing is one of the research priorities in the future.

China's relevant industrial sectors have introduced a number of high-grade sub-water cutting systems from abroad for cutting titanium alloys, aluminum alloys, stainless steel, carbon fiber, aerospace glass and composite materials. However, due to problems such as slow processing speed, low processing efficiency, and unsatisfactory processing accuracy, it has not been widely used in China. Studying the process technology of high-pressure water jet cutting, it can improve the processing speed and improve the processing precision by optimizing the process, laying a foundation for the popularization and application of high-pressure water jet cutting, and further improving the processing level in the field of material cutting, especially special material cutting. Ultra-high pressure water jet cutting technology is a green manufacturing technology that conforms to the current sustainable development trend. It is a new type of cold high energy beam cutting technology. It is a new technology developed rapidly in the past 20 years and its application is very extensive. . The development of ultra-high pressure water jet technology reflects that the concept of green manufacturing is gradually gaining popularity among people and is increasingly being valued by people. It is considered to be the mainstream cutting technology for priority development in the 21st century. As a green cutting tool in the 21st century, the ultra-high pressure water jet cutting machine has many advantages, and it has great application prospects. It will develop in the direction of high efficiency, multi-function, intelligence, high precision and environmental protection. As a "world manufacturing center", China should arm its cutting tools as soon as possible to achieve higher levels of productivity.

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