Water Jet Cutting

Introduction
This article takes an in depth look at water jet cutting.

You will learn more about topics such as:

• What is water jet cutting?

• The water jet cutting process.

• Types of water jet cutting cuts

• Types of water jet cutting

• Uses for water jet cutting.

• Water jet cutting machines.

• And much more…

Chapter One – What is Water Jet Cutting?

Water jet cutting is a manufacturing process that uses high pressure
jets of water provided by pressurizing pumps that deliver a supersonic
stream of water to cut and shape various types of materials. The water
in water jet cutting is pressurized to 392 MPa and projected using a
small precision nozzle. As the water leaves the nozzle, it reaches
speeds that are three times the speed of sound.
Pure water jet cutting with water as its medium is designed for soft
materials such as wood, plastics, foam, paper, and rubber. When an
abrasive is added to the water stream, such as titanium, stainless steel,
aluminum, glass, ceramic material, and concrete, cutting becomes
more aggressive and capable of cutting hard metals.

Chapter Two – How Water Jet Cutting Works

The water jet cutting process can be completed in several different
ways. Most of the methods have an abrasive blended into the water to
cut particles from the workpiece. It is a very versatile manufacturing
process that can be used to cut, shape, and design a workpiece to meet
exact specifications.
The shaping method used for water jet cutting has several advantages
over other cutting processes, such as plasma or laser. Water jet cutting
has better accuracy, can cut complex designs, and is able to cut
thermally sensitive surfaces. The abrasive is like sandpaper and
erodes the material being cut. It does not heat the material or change
its temper. The cut edges are clean and can be welded without the
need for further processing.

The Process of Water Jet Cutting

Measuring Kerf Width

Kerf width relates to the material being removed as a part of a cutting

process. The term was originally used to refer to the material removed
by the cutting of a saw blade. In the case of a water jet cutter, it refers
to the width of the stream, which is normally 0.04 inch or smaller. The
inside corners cut by water jet cutting have a radius that matches the
width of the stream. The kerf depends on a variety of factors, which
include material thickness, type of material, cutting quality, and the
nature of the waterjet nozzle.
The size of the kerf is an important design factor that has to be
accounted for when determining the dimensions of the final product.
If the kerf is 0.042 inches, the dimensions of the final part have to be
adjusted to account for the cutting width or the final part will be 0.042
inch off.
Initial Water Jet Piercing
The first cut made by a water jet cutter is referred to as the pierce,
which is wider than the normal kerf. The initiation of the pierce is the
first step in the water jet cutting process. It can be completed in
several different ways with stationary, linear, circular, and low
pressure being the most common methods. Which of the piercing
methods is used is dependent on the material to be cut and the amount
of scrap produced.
Tapering in Kerf Width
Tapering in water jet cutting refers to the kerf width at the top of the
cut and its width at the bottom. Water jet cuts have a V-shaped taper,
which is generated because the stream loses some of its energy as it
cuts deeper into the material, with more material being removed at the
top than at the bottom.

Slow cutting speeds produce a reverse taper where the kerf width is
wider at the bottom, which is caused by removing more material at the
bottom of the cut. The reverse taper can be seen when cutting soft,
pliable materials.

Barrel tapers are created when the cut is widest in the middle of the
cut, which occurs when cutting extremely thick materials.

For most cutting, tapering does not matter and can be used as a benefit
for certain jobs. In the case of precision tooling where cut pieces must
fit together accurately, tapering can be a problem and needs to be
taken into consideration.
Pressurizing the Water
Several methods are used to pressurize the water, including linear
intensifiers and rotary direct drive pumps. The two types of pumps
have a motor, water filters, control systems, and sensors.

Linear intensifier pumps use pressurized hydraulic oil at a pressure of

3000 psi. Low pressure oil pushes against a piston that has a face area
that is 20 times larger than that of the high-pressure plunger that
pushes against the water. Since the size of the low-pressure pump is
20 times larger than that of the high pressure one, the pressure on the
larger plunger is intensified 20 times, yielding a pressure of 60,000 psi.

A direct drive rotary pump does not include hydraulic oil. It has
an electric motor that rotates a crank that drives pistons that generate
the water pressure. Direct drive pumps have 30 hp motors with an
inlet that supplies water to the pump.
High Pressure Tubing
The pressurized water from the pump travels through high pressure
tubing to the cutting head. High pressure tubing has excellent yield
and tensile strength with an exceptionally smooth interior surface. It
is produced from cold worked stainless steel or thermoplastic pressure
hose in sizes from 0.25 inches up to 0.563 inches and comes in a wide
variety of lengths to fit the design of the water jet cutter.
Water Jet Cutting Head
The pressurized water passes through the orifice of the cutting head,
which is a diamond, ruby, or sapphire with a hole smaller than the
point of a pin. As the water passes through, its velocity radically
increases to over 90,000 psi or 2500 mph. The cutting process is
directly affected by the power provided by the cutting head. A
precision tooling cutting head, when used properly, can last from 500
to 1000 hours.

The image below has an example of two cutting heads, which are
water only and water with abrasive. The difference between the two
types can be seen in the red tube carrying the abrasive to the water
stream.
Pure Water Jet Cutters
Pure water jet cutters are the original form of water jet cutting tool.
They are used since they create less moisture on the surface of the
workpiece than is created by touching it. They have a thin stream that
cuts excellent detailed geometries with limited material loss. The
construction of a pure water jet cutter has a jewel with rubies being
excluded and unsuitable for work with pure water. The stream travels
at Mach 2 for 40,000 psi and Mach 3 for 60,000 psi.

Abrasive Water Jet Cutting System

In the abrasive water jet cutting system, an abrasive material is fed

into the cutting head, where it is mixed appropriately with the water
stream. The introduction of an abrasive makes the stream sharper and
creates more effective cutting. The addition of an abrasive makes a
water jet cutter capable of cutting anything regardless of its hardness
or thickness.
With an abrasive water jet cutter, the stream accelerates the abrasive
material that erodes away the surface of the material being cut. An
abrasive water jet cutter is 1000 times more powerful than a pure
water jet cutter. The stream is larger in diameter and capable of
cutting materials that are ten inches thick without creating heat or
mechanical stress.
Chapter Three - Types of Water Jet Cuts
In many ways, the cutting process, regardless of the method, is very
straightforward where a piece of material is severed using a cutting
tool. As can be expected, this is also true of water jet cutting, which can
perform cuts much like a band saw. The process of cutting in modern
manufacturing is far more complex, complicated, and advanced than
that which resembles the old band saw.

Water jet cutting machines can be programmed to perform a wide

variety of cuts depending on the needs of the application. They can
perform traditional single cuts and 2, 3, 4, and 5 axis cuts.

Types of Water Jet Cuts

One Dimensional
One dimensional water jet cut are stationary cuts performed in one
pass of the workpiece through the water jet cutting mechanism. They
are the simplest form of cut and used for trimming. The operator feeds
the workpiece into the cutting tool while the debris and water are
caught on the other side. A variation of the one-dimensional cutter is a
slitter that cuts pieces to specific widths. One dimensional cutter can be
pure water or water with an abrasive.

Two Dimensional - XY
Two-dimensional cutting requires the use of PC or CNC programming.
They have a servo motor with closed loop feedback to control
positioning and cutting velocity. Catcher tanks are water filled and have
slats to support the workpiece. The Z portion of an XY two-dimensional
cutting machine controls the height of the cutting device to adapt to the
variations in the thicknesses of the workpiece.
Two-dimensional cutting is ideal for rapid and fast cutting of different
materials and parts.

Three Dimensional XYZ

Three-dimensional cutting involves the use of the X axis that moves left
to right, the Y axis that moves front to back, and the Z axis that moves
up and down. In the three-axis process, the workpiece remains
stationary while the cutting tool moves along the three planes. It is a
process used to produce mechanical components.

Four Dimensional - XYZA

In four-dimensional cutting, the workpiece is processed by the three

axis of XYZ but includes a fourth dimensional rotary motion around the
X axis. The cutting along the A axis allows the workpiece to be cut along
the B axis. It is an excellent method for cutting in the sides of a
workpiece of holes or other openings. The addition of the A axis offers
the option of automatically flipping the workpiece to allow the waterjet
to remove material from both sides of the workpiece.

Five Dimensional - XYZAB

The power and convenience of a 5-axis system allows the workpiece to

be manipulated along five axes at one time. The workpiece is moved
along the two-dimensional XYZ axes. Additional rotational movements
are added that travel around the XYZ axes, which are A, B, and C axes
that perform 180o rotations around the X, Y, and Z axes. The use of this
type of cutting allows for the fabrication of extremely complex solid
components.
The process of five axis machining requires a great deal of CNC
programming preparation to account for the multiple rotary
movements. Its major benefit is the ability to work one workpiece on
five sides in a single operation. Five axis machining is beneficial for
producing components with intricacies and details with exacting
precision.

Chapter Four – Types of Water Jet Cutting

The concept of water jet cutting is rather simple and involves pressure,
velocity, and an abrasive. Though the process is not complicated, how it
is applied varies widely. The many variations have been developed to
meet the exact specifications for different applications.

The types of water jet cutting are divided between pure water and pure
water with an abrasive. From these two classifications, the process is
further divided according to several factors.

Water Jet Cutting Types

Abrasive Flow Machining (AFM)
Abrasive flow machining is an interior surface finishing. The use of AFM
is necessary for deburring and honing of the interior of parts that
traditional deburring methods cannot reach. As the water and abrasive
contact raised surfaces on the interior of a workpiece, it erodes the
surface removing the unwanted particles much like a grinder or
sandpaper.
Abrasive Jet Machining

The abrasive jet machining process is the essence of abrasive water jet
cutting and includes a high pressure stream of water with an abrasive.
It blasts and erodes the workpiece to remove particulate matter, burrs,
and materials. As is common with abrasive water jet cutting, the
particles used for cutting are extremely fine and applied at high
velocity. It is a process that is used to cut and shape brittle, thin, and
hard materials. Abrasive jet machining is used to cut intricate shapes
and form smooth, even edges.
High Pressure Water Cutting
Using intensifiers, the pressure of pure water is radically increased such
that it can shape and form soft materials without leaving a water
residue. The intensification of the water flow is created by hydraulic
pumps that harness the force of the water and change it into
mechanical energy.

A major advancement in high pressure water jet cutting occurred by

introducing corundum elements in the cutting head, which are varieties
of rubies and sapphires. Corundum is very hard, tough, and stable. It is
unaffected by acids and is the second hardest mineral on earth.

CNC Water Jet Cutting

CNC water jet cutting employs the same methods of high-pressure

water but is programmed to do multiple operations during one pass.
The main use of CNC water jet cutting is in situations where the
material to be shaped and cut is sensitive to high temperature
processes. Some of the cycles a CNC water jet cutting machine passes
through are cutting, forming, deburring, reaming, and honing, which
are operations that are best suited for the water jet cutting process.

The majority of CNC water jet cutting machines are three axes and
perform functions along the X, Y, and Z axis where the X axis moves left
to right, the Y moves front to back, and the Z moves up and down. A
recent addition to CNC water jet cutting machines is the five axes model
that has a rotation around the X axis called the A axis and a rotation
around the Y axis referred to as the B axis.
Chapter Five – Uses for Water Jet Cutting

The water jet cutting process has gained popularity due to its precision
and fast turnaround times. The quality and performance of water jet
cutting have made it the preferred cutting method for several
industries, especially those that require precise and highly accurate
tolerances.

Since its inception in the 1950s and the improvements in the 1970s,
water jet cutting has been steadily becoming an essential part of
industrial operations. The simple fact that there isn’t any heat involved
is sufficient reason for its wide use.
Water Jet Cutting Uses

Water Jet Cutting in the Aerospace Industry

All components for aerospace require complex and accurate precision.

The dictates of aerospace do not allow for any type of error. It is for this
single reason that water jet cutting is an essential part of aerospace
part production from the manufacturing of jet engines to custom
designed control panels.

Abrasive water jet cutting is used in the aerospace industry for cutting
steel, brass, Inconel, and aluminum. The metals cut by the process are
used for wing sections, turbine blades, brake components, and landing
gear and are used to cut forms that are eight inches thick.
Auto Industry

A key factor regarding the use of water jet cutting in the auto industry is
its ability to be integrated into robotic systems. Both methods of water
jet cutting are used with pure water jet cutting being used to shape
interior carpets, insulation, and head linings. Pure water jet cutting
produces minimal material waste and undoes cleanup.

Water jet cutting does not have heat affected zones (HAZ), generates
noxious fumes, or creates stress on the workpiece but produces
smooth burr free surfaces that eliminate the need for secondary
finishing.

Water Jet Cutting in Medicine

In medicine, water jet cutting technology is being used to replace

surgical cutting tools. The high-pressure spiral water crushes and sucks
liver parenchymal cells in the treatment of tumors. It is selected to
perform these functions since it does not produce heat that would
damage other organs and minimizes the chance of bleeding. Changing
the pressure and flow rate makes it possible to dissect human tissue
with less trauma, bleeding, and postoperative problems.
Cutting of Glass

Much like the medical field, water jet cutting of glass is used due to the
ability to modify, adjust, and change the cutting stream. Cutting glass is
a very delicate process that requires precision tools to avoid puncturing
or breaking the glass. The ability of water jet cutting to cut glass without
damaging the glass’ internal structure leads to smooth and efficient
cutting. The omnidirectional stream can cut any shape, form,
configuration, or workpiece down to the finest detail. The high-
pressured stream creates pinpoint accuracy, making it capable of
cutting holes, notches, and structures without distortions.

Water Jet Cutting in Industrial Cleaning

Various industrial processes produce unwanted materials during the

performance of the process. Additionally, industrial storage tanks and
conduits require cleaning due to the accumulation of flakes, scales, and
rust. Though highly caustic cleaners can remove built up matter, they
may not be applicable for all circumstances. The high speed, pulsating
blast from a high-pressure water jet cutting device can safely remove
and clean industrial equipment, storage units, and piping.
The energy produced by a water jet cutter is much higher than the
energy necessary for scales, coatings, or contaminants to adhere to a
contaminated surface. It is an exceptionally safe, cold cutting method
for industrial cleaning. A key factor for its use is its efficiency and speed,
eliminating down time and work stoppage.

Food Industry Cutting

Water jet cutting of food is a United States Department of Agriculture

(USDA) approved method of cutting that provides productive and
sanitary benefits. Much like other industrial uses of water jet cutting the
food industry depends on water jet cutting for its precision and
assistance with portion control. A water jet cutter can cut meat, fish,
poultry, pastries, and frozen foods to precise and perfect shapes.

The key feature for water jet cutting of foods is the pure clean water
that is central to its operation. The speed at which water jet cutters
operate allows for efficient and rapid processing of food products.
Water Jet Cutting Electronics

A major issue in the production of electronics is cost. Manufacturers

are constantly searching for ways to reduce costs while increasing
efficiency. The cost effectiveness and efficiency of water jet cutting have
made it an essential part of electronics production. The process can be
used for cutting circuit boards whether the board is populated or
empty. It is also an effective method for stripping wires without the
worry of damaging the wire.

Water Jet Cutting Fiberglass

Safety is the key issue with fiberglass handling, which requires

precision, efficiency, and accuracy. Water jet cutting is capable of
shaping and forming fiberglass without the creation of dust or waste.
Cuts are made quickly to the precise dimensions of the application.
There are few limitations on the rigidity of the fiberglass being cut
whether it is for shaping insulation or for shaping and forming of boats.
Fiberglass is delivered in precision cut shapes, which are formed using
water jet cutting.
Chapter Six – Types of Water Jet Cutting Machines

Water jet cutting machines have the water jet cutting process attached
to a large controllable mechanism, including a high-pressure pump,
controller, catch tank, an X Y movement system, and abrasive or pure
water nozzle. A key component to a water jet cutting machine is motion
control that serves the multiple functions of controlling the motion of
the cutter and providing a method for holding the workpiece in place.

There are several types, sizes, designs, and processes used to produce
water jet cutting machines. Many of the different varieties have CNC
controllers that further enhance the cutting process and its precision.

Water Jet Cutting Machine Types

Computer Numerical Control (CNC)

A very common part of modern manufacturing is the computer

numerical control (CNC) machine that can be programmed to perform
multiple tasks in one pass over a workpiece. The use of CNC
programming for water jet cutting has been widely used for many years
and is a combination of the finest cutting process with precision
control.

The main use of CNC water jet cutting is in situations where the
material to be shaped and cut is sensitive to high temperature
processes. Some of the cycles of a CNC water jet cutting machine
include cutting, forming, deburring, reaming, and honing, which are
operations that are best suited for the water jet cutting process.
A CNC water jet cutting machine has all the properties and
characteristics associated with water jet cutting. The machines used for
CNC water jet cutting are normally flatbed machines with CNC
programming connected to the machine’s components. CNC water jet
cutting machines are flexible and versatile enough to be customized to
fit any production need.

Flatbed Water Jet Cutting Machines

Flatbed water jet cutting machines have a working table that allows for
the cutting of large pieces. The flatbed design permits easy access to
the table for loading and unloading of materials. A main feature of
flatbed water jet cutting machines is their ability to collect the water
from the cutting process as well as any waste matter. Water jet cutting
flatbed machines are used for their low cost, ability to cut any type of
material, and the absence of heat. Parts for water jet cutting keep their
heat treatment when placed in the cutting process, which removes the
need for heat treatment after being cut.
Computer Numerical Control (CNC)

A very common part of modern manufacturing is the CNC machine that

can be programmed to perform multiple tasks in one pass over a
workpiece. The use of CNC programming for water jet cutting has been
widely used for many years and is a combination of the finest cutting
process with precision control.

A CNC water jet cutting machine has all of the properties and
characteristics associated with water jet cutting. The machines used for
CNC water jet cutting are normally flatbed machines with CNC
programming connected to the machine’s components. CNC water jet
cutting machines are flexible and versatile enough to be customized to
fit any production need.

Portable Water Jet Cutting

Portable water jet cutting machines are a low cost, environmentally

safe, and flexible cutting method for cleaning contaminated surfaces,
removing burrs, and cutting off the rust. They are suitable for use in
dangerous and hazardous conditions, such as the oil industry,
construction tunnels, and pipelines. Portable water jet cutting machines
have all the features of high-pressure water and velocity and can cut
any type of material.
The two types of portable water jet cutting machines are differentiated
by how they insert the abrasive into the water stream. One method is
to supply the abrasive at the time it is released through the nozzle. The
second less effective type is to premix the abrasive with the water
before it gets pressurized.

Chapter Seven – Products Made Using Water Jet Cutting

There is an endless list of products, parts, components, and materials

shaped and machined using water jet cutting. From highly precision
parts for aerospace to decorative ornaments for the home, water jet
cutting is relied on to produce precision cuts and precise dimensional
accuracy.

The list below contains a few examples of items that have been
produced using water jet cutting. Included in the many uses of water jet
cutting is the placement of logos on final products and on the surface
of hard materials.
Water Jet Cut Products

Wooden Electric Guitar

Using a CAD drawing, the outline of a guitar body is placed on the

workpiece. The piece of wood is fed into the water jet cutter. Since
water jet cutting does not place a load on the workpiece, it is capable of
cutting delicate wood without damaging the grain.

Making Gears

A common product that is manufactured using water jet cutting is gears

due to the precision and accuracy they require.
Using Water Jet Cutting on Cams

Cams can easily be made using water jet cutting. All that needs to be
determined is the desired shape. Once the CAD rendering is loaded, the
water jet cutting machine quickly and easily cuts it.
Producing Chains

Chains produced using water jet cutting are designed to handle heavy
loads of several tons. The links are produced using water jet cutting and
assembled into chains to lift exceptionally heavy loads.

Creating Name Plates

Water jet cutting is used to create permanent name plates out of heavy
metals. The process is used to produce name plates, signage, and
company logos. The main reasons for using water jet cutting are due to
its precision, removal of the need for finishing, and the smooth edges
and finish.

Water Jet Cutting Rubber

Water jet cutting of rubber is far easier than any other cutting method
and can cut any thickness. It can cut through rubber back metals to
streamline the manufacturing process. Water jet cutting does not
require special tooling or dies and completes rubber cutting with
precision, speed, and optimization of materials.
A unique feature of the water jet cutting of rubber is stack cutting,
where several workpieces are piled on top of each other and cut with
one pass.

The six items listed above are an extremely small sampling of the
products, parts, components, and materials that are fabricated by
water jet cutting. With the many advancements in technology and
cutting techniques, water jet cutting has become essential for efficient
and streamlined industrial operations.

Chapter Eight – Advantages of Water Jet Cutting

There are innumerable methods for cutting, shaping, and forming of

industrial products that are capable of performing numerous cuts in a
variety of dimensions. Each of those methods has one significant
disadvantage, which is the amount of heat they produce during the
cutting process. Even the shearing process produces friction during
cutting that creates heat.
With water jet cutting, the workpiece remains cool while being cut
accurately and precisely. It is a cold process where the molecular
structure does not change, and thermal stress does not occur.

Water Jet Cutting Benefits

Extreme Precision

The precision and accuracy of water jet cutting is unbelievable, with a

cutting accuracy between ± 0.003 inch to ± 0.005 inch. Since the cutting
speed can be altered mid cut, parts can be cut with multiple edges.

Secondary Finishing

Water jet cutting does not create rough surfaces, burrs, or

imperfections, which removes the need for secondary finishing. It
produces minimal kerfs and smooth finishes. The smoothness of
finishes results from the use of erosion to remove material instead of
heat or shearing.

Versatility Advantage

There is a limitless number of uses for water jet cutting since it is

capable of cutting any material regardless of its hardness. It cuts
materials without altering their mechanical properties or weakening
their integrity. For increased efficiency, thin materials can be stacked
and cut to increase productivity and further lower costs. Additionally,
water jet cutting machines come in a variety of table sizes to match the
many sizes of workpieces.
Environmentally Safe

Being green is a factor for every manufacturer and industry. The effects
of the efforts to preserve the environment have affected other cutting
methods except water jet cutting. Most cutting methods produce
waste, particulate matter, and pollutants, which are not produced by
water jet cutting.

Water jet cutting does not produce toxic gases, harmful waste
materials, or poisonous contaminants. It uses pure water that is
augmented with natural abrasive materials. Leftover matter from the
process can be discharged without damage to the environment.

Ease of Use

The process of water jet cutting involves using a water pump and
cutting tool to produce a high velocity water stream at three times the
speed of sound. The same components are used to create any type of
cut in any type of material.

This lack of complexity makes water jet cutting a cost effective and
economical production method whether the cuts are 2D or 3D objects.

Programming Shape

The programmed shape created by engineering software easily

transfers into the controls of the water jet cutting machine. The entered
data is used to produce precise positioning, cutting speed, and cutting
angle. Once the specific of the material is entered, the machine rapidly
completes the cutting process.
Cost Savings of Water Jet Cutting

Of the many positive attributes of water jet cutting, cost savings is the

most significant and prominent. The cost of running a water jet cutting

machine is far less than any other cutting process. Added to running

cost benefits are fast transition times, the speed of the cutting process,

and ease of setup.

Lack of Chemicals

The only fluid used in water jet cutting is water and an abrasive that

erodes away the material. The jet stream of water cools any heat that is

produced. Warping, distortion, and hardening are not factors, which

further minimizes secondary processing. Water jet cutting is safer for

workers and operators since it does not produce vapors.

Water Jet Cutting Efficiency

Water jet cutting is the most efficient cutting method due to its power

and handling of materials. Much of its efficiency can be seen in

recycling the water it uses and the removal of the need for secondary

processing. Since it can cut anything, tooling does not have to be

changed when moving from one product to the next.

Product Control

Precision water jet cutting offers better control of the cutting

process such that workpieces can be cut to the sizes and

dimensions that are required. It is a more manageable

method compared to cutting with a blade or saw.

Sanitary

Water jet cutting is ideal for the food industry since it does not

involve the use of chemicals, cutting tools, or any material that

would meet food. Under the present restrictions requiring

extreme cleanliness and sanitation, water jet cutting is ideal

for food processing cutting with standards that demand zero

cross contamination.