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THE ORIGINS OF THE NEW APPROACH If waterjet technology offers so many advantages, why has it taken so long to be developed? It has, in fact, taken more than 20 years of research, thousands of man-hours, and millions of dollars of effort to develop the new system, whose current level of sophistication was only made possible by the advent of computerized automation techniques. Development efforts began over 20 years ago in the manufacturing industry, as engineers searched for improved cutting methods to handle all sorts of hard and soft materials coming off assembly lines. As early as 1961, patents were issued for systems using abrasive and non-abrasive waterjets. The non-abrasive waterjet cutting system became a practical reality first. Using a simple high-pressure stream of water, it was used by companies to cut soft substances such as paper and frozen foods. As the technology evolved, however, engineers developed abrasive waterjet systems as well. These processes worked by adding an abrasive material to the high-pressure water stream and could be used to cut much harder substances, such as glass or composite materials. |
The latest innovation in waterjet technology uses abrasive material in an extremely precise waterjet stream. Searching for the optimal method of cutting composite materials, researchers investigated computer-operated cutting systems. Aware of the superior ability of abrasive waterjets to cut thicker materials and leave cleaner edges, the engineers wanted to try a new twist: a cutting process that combined computer-controlled cutting methods with waterjet methods. The resulting technology, used today by World Marble Designs, contains three major components. The waterjet system comprises the first element. It consists of a high-pressure waterjet capable of pumping water up to 60,000 pounds per square inch. The very precise water stream is first mixed with an abrasive mixture, then shot out of a carbide nozzle at twice the speed of sound to perform the cutting operation. The cutting head can start cutting from any location on the stone; it is not limited to starting on the edge of the stone. |
The cutting process takes place on a special table, which constitutes the second aspect of this new waterjet technology. This table moves the waterjet cutting action on one axis and materials to be cut on another axis. A narrow slot under the cutting stream of water directs the force of the stream into a special holding tank, which diffuses the energy of the waterjet from cutting holes in the floor under the cutting table. To coordinate movements between the two axes on the cutting table, the third component-computer technology-comes into play. The computer technology used by World Marble Designs integrates computer-aided design and computer-aided manufacturing (CAD/CAM) to coordinate every aspect of the cutting process. For example, the computer not only automates generation of the cutting design, but also directs the cutting operation (from jet pressure to cutting speed), controls loading and unloading of materials, and even handles miscellaneous functions such as safety interlocks. The entire process may sound complicated, but it is actually very economical and relatively effortless. |
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