Explore the architecture of a 5-axis waterjet, from the UHP pump (~550 MPa) to the AB-axis head, nozzle specs, and control system for precision cutting.

Understanding the core architecture of a CNC waterjet is key to leveraging its full potential. The machine’s ability to deliver bevels and complex contours in brittle materials without heat-affected zones (HAZ) stems from a precise integration of an ultrahigh-pressure (UHP) system, a sophisticated cutting head, and a rigid gantry structure.

The DINOSAW 5-Axis CNC Waterjet Cutter integrates a gantry cutting table (with models like 3020 and 4020), a UHP pump, a 5-axis AB-axis head, an automatic sand feeder, and a CNC control cabinet, offering a complete system for precision manufacturing.

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5 Axis Waterjet Cutting Principles

The fundamental principle of abrasive waterjet cutting is material erosion. The process starts at the UHP pump, which pressurizes water to extreme levels. This water is then forced through a tiny orifice (the nozzle) to create a supersonic stream. For cutting hard materials, an abrasive garnet is drawn into this stream in a mixing tube, and the resulting slurry exits the cutting head to precisely erode the workpiece.

Nozzle (0.05–0.33 mm) & Mixing Tube (ID ~1.02 mm)

The nozzle, typically made of ruby or diamond, is a critical component that focuses the water jet. DINOSAW-reported diameter ranges from 0.05 mm to 0.33 mm, with smaller orifices used for finer details. After the nozzle, the water passes through a mixing chamber where it creates a vacuum that pulls abrasive from the feed line. The water and abrasive combine in the mixing tube (sand tube), which has a typical inner diameter of 1.02 mm, before striking the material.

AB-Head/AC-Head Kinematics vs 3-Axis

While a 3-axis machine operates on the X, Y, and Z planes for 2D profiling, a 5-axis machine features an articulating AB-axis/AC-axis head. This allows the cutting head to tilt and rotate, enabling the machine to cut complex 3D shapes, beveled edges, and compensate for taper, which naturally occurs in thick materials. This is essential for applications like weld preparations and creating seamless mitered edges on countertops.

Servo Speeds (X/Y ~6000 mm/min), Z-Travel ~90 mm

Motion is controlled by high-precision servo motors. The gantry system allows for rapid positioning, with X and Y axis running speeds up to 6000 mm/min . The Z-axis travel of approximately 90 mm provides ample clearance for various material thicknesses and fixtures, and includes an infrared altimetry function for maintaining a consistent standoff distance from the material surface.

UHP Pump Control & Cooling Tower

The heart of the system is the UHP intensifier pump, which can achieve a rated pressure of 550 MPa , though typical working pressures range from 350–390 MPa. This pressure is generated by a hydraulic system driving a plunger assembly. During operation, oil temperature can rise, affecting seal life and performance. A cooling tower is integrated to maintain stable oil temperatures, prolonging the life of high-pressure components and ensuring consistent pressure delivery.

HMI/Interlocks Integration

The entire system is managed by a CNC controller with an intuitive Human-Machine Interface (HMI), available in Chinese and English. The software automates complex calculations, such as cutting time, and controls parameters like pierce delays and feed rates. For safety and process control, the system includes multiple interlocks and is designed for compatibility with standard factory automation hardware like PLCs and drives.

Key Components and Common Failure Modes

High-Pressure Seals

These are wear items inside the pump.

  • Failure Mode: Gradual wear leads to a noticeable drop in pressure and water leaks.

  • Mitigation: Follow the preventive maintenance schedule and use seal kits for replacement.

Nozzle/Mixing Tube

The abrasive stream erodes these components over time.

  • Failure Mode: A worn nozzle or tube results in a diffused cutting stream, causing poor edge quality and reduced accuracy.

  • Mitigation: Regular inspection and timely replacement.

Abrasive Feed Line

Moisture or inconsistent abrasive can cause blockages.

  • Failure Mode: Clogging leads to an unstable or nonexistent abrasive flow, preventing the machine from cutting.

  • Mitigation: Use high-quality, dry abrasive and regularly check the sand valve and feed system.

Frequently Asked Questions

What nozzle size is best for cutting sintered slabs?

A smaller nozzle orifice (e.g., 0.25mm) paired with a corresponding mixing tube is often preferred for fine details and better edge quality on brittle materials like sintered stone.

Why does seal wear affect cutting pressure?

Seals are critical for maintaining pressure in the UHP pump. As they wear, water can bypass the seal, causing a pressure drop and reducing cutting efficiency.

How do you map safety interlocks to a factory PLC?

The machine's control cabinet provides I/O points that can be wired to a central PLC to monitor states like emergency stops, pump status, or cover open/closed, ensuring safe integration.

When is an AB-axis/AC-axis head necessary?

An AB-axis/AC-axis head is essential for creating beveled edges, performing taper compensation on thick parts, and cutting complex 3D shapes. For simple 2D cutting, a 3-axis head is sufficient.

Should the cooling tower be upgraded for continuous operation?

For shops running the machine for multiple shifts in a warm climate, upgrading the cooling tower or ensuring it is properly sized is recommended to maintain optimal hydraulic oil temperature and protect the pump.