Advanced Engineering Birmingham - /en/exhibitors/ - Advanced Engineering Birmingham

Aquajet Machining Systems Limited

OMAX Waterjet Machine Partner, Aquajet offer a complete range of OMAX CNC precision WATERJET MACHINES along with genuine OMAX accessories and consumables. Aquajet is part of a global network and can rely on 3 decades of knowledge and experience of high pressure cutting systems. Utilising the latest technology from OMAX® Corporation, Aquajet are able to offer sub-contract machining to some of the tightest tolerances in the industry and have a highly skilled team of factory certified technicians which ensures we are ideally placed to assist you either in a sub-contract service or as a machine customer. We work with many blue chip companies throughout the UK, Ireland and Iceland. We specialise in short batch runs and tight tolerance machining. Our manufacturing facility is equipped with state of the art OMAX machining centres. Aquajet complies to Quality standard ISO 9001:2015. Waterjet cutting technology is one of the fastest growing major machine tool processes in the world and its versatility has also allowed us to support the rapid growth. Waterjet machining has been around for decades and is one of the fastest growing machining processes today. Its ease of use and its ability to cut almost any material while maintaining high precision make it suitable for a large array of operators, from small short-run job shops and R & D facilities to large corporations engaging in full-scale production to trade schools teaching manufacturing methods. A waterjet utilises a high pressure stream of water to erode a narrow line in the stock material. To cut a wider range of materials from tool steel to titanium to foam, a granular (typically garnet) abrasive is added to the waterjet, increasing the cutting power. Because the abrasive is added at the nozzle, it is simple to switch between water only and abrasive waterjet cutting . This flexibility greatly enhances the versatility of a waterjet machine, as it can easily switch from cutting ½” (1.27cm) foam gaskets to 4” (10.16cm) titanium brackets. Motion Control – Accurate First Cut The motion control system is an essential element in an abrasive waterjet cutting system because the cutting stream bends as it cuts. This means that a waterjet tends to undercut corners and swing wide on curves when moved as one would move a traditional rigid cutting tool. OMAX eliminates this issue by using an advanced computer model to accurately predict the motion and shape of the cutting stream and then by using a PC-based motion control system to compensate for undesired jet motion. The result is a fast, accurate part the first time. No trial and error and no need for an experienced programmer because the experience and the knowledge is in the control software. Pumps Waterjet cutting systems utilise either the older, more complex hydraulic intensifier pump or the newer, simpler crankshaft-driven triplex plunger pump. Crankshaft pumps are inherently more efficient than intensifier pumps because they do not require a power-robbing hydraulic system. The crankshaft drive is a purely mechanical direct-drive system with minimal friction losses and so efficiencies between 85% and 90% are typical. This means that 85% or more of the electric power supplied to the drive motor can actually be delivered to the cutting nozzle, compared to the typical 65% or less of an intensifier. Historically intensifier pumps had an advantage of longer seal and check-valve life, but ongoing improvements in seal designs and materials and the wide availability and reduced cost of ceramic valve components now make it possible to operate a crankshaft pump in the 60,000 PSI (4,137 bar) range with long maintenance intervals and excellent reliability. OMAX uses high-efficiency crankshaft-driven direct-drive pumps exclusively for all of its systems. A direct-drive pump is more efficient than a traditional hydraulic intensifier pump and so it can deliver more net power to the cutting nozzle, resulting in faster cutting. It is quiet and clean, with no risk of messy hydraulic leaks. In addition, a direct-drive pump is simple to understand, to troubleshoot and to maintain. The OMAX Enduromax pump features a preventative maintenance interval of 1000 hours, offering the ultimate in reliable low-cost operation. Abrasive-waterjet-nozzleAll abrasive waterjet nozzles use the basic operating principle of the aspiration nozzle, first patented in 1937 (Patent 2,131,660) and shown in its modern configuration in the diagram on the right. In order for the aspiration nozzle to cut efficiently and with long component life, it is critical that the orifice be carefully aligned with the centerline of the mixing tube. All OMAX nozzles are factory-aligned and individually tested to assure efficient cutting and long life. What Materials Can a Waterjet Cut? Waterjets are capable of cutting composites, metals, glass, stone, concrete, ceramics and rubber. Composites Carbon Fibre Reinforced Plastics Cutting this advanced material is a major growth area for OMAX systems. The material cuts very quickly and cleanly and the OMAX abrasivejet system is now widely used in applications from aerospace components to race cars, from NASA to NASCAR. Cutting carbon fibre reinforced plastics with an OMAX abrasive waterjet has major advantages, such as no tool clogging or wear, no need to change tooling, no special considerations or restrictions due to heat buildup, no melting, and no hazardous fumes requiring costly air handling equipment. Glass-Reinforced Plastics Fibreglass can be cut quickly and cleanly without hazardous dust or fumes by simply submerging the material during cutting. Other-Reinforced Plastics Any fiber-reinforced material, including Kevlar reinforced personnel armor, can be quickly and cleanly cut on the OMAX without hazardous dust or fumes. Metals Carbon Steel The OMAX® waterjet machine will cut all grades of steel. It produces a smooth cut on the edge without burn marks, cracking, excess burr, or other problems typically associated with heat-based cutting or mechanical cutting. The lack of heat affected zone from the abrasivejet means that the heat treatment of the steel is not changed by the cutting process. Stainless Steel All grades of stainless steel can be cut easily on the OMAX, even those such as 304 that are difficult to machine with other processes without heat or distortion. A heat affected zone can weaken integrity of a part and lead to failure. The lack of any Heat Affected Zones makes the abrasivejet process particularly attractive to those producing food processing and handling equipment or the aerospace industry. Polished or reflective surfaces do not negatively affect the abrasivejet process as they might with a laser cutting system. Hardened Tool Steel Tool steel can be cut in a fully hardened state without any change in material properties. More and more tool and die shops are finding the OMAX system to be a valuable addition with close to EDM precision at up to 10 times the speed. Alloys of All Types Difficult-to-machine special superalloys, such as Inconel® and Hastelloy® are easy to cut without heat or distortion on the OMAX. Aluminum Probably more aluminium is cut on OMAX systems than any other metal because it cuts so quickly and cleanly, without any thermal distortion. More and more laser specialty shops are adding an OMAX system to their mix of lasers in order to accurately cut thicker aluminium. Titanium The OMAX system is ideal for cutting titanium, which can be a challenging material for conventional machining processes. Titanium can be cut quickly and accurately without any thermal distortion or surface embrittlement. Because titanium is so expensive, considerable cost savings can be obtained by the close nesting of parts that is possible with the abrasivejet process in order to reduce waste material. Copper All grades of copper cut quickly and cleanly on the OMAX without thermal distortion. The reflectivity that may be an issue for lasers is not a problem for an abrasivejet and there is no problem with “gumming” as might occur with conventional mechanical cutting systems. Brass Brass alloys cut quickly and cleanly with the OMAX abrasivejet process, with no thermal distortion. Glass The OMAX system is widely used for cutting a wide variety of glass products, from ultra-thin panels for smartphones to thick multi-layered bullet-proof panels for vehicles and buildings to panels for stained glass windows. The OMAX has the capability perform a low pressure pierce that automatically switches to high pressure mode to continue the tool path. This means that even the most brittle glass can easily be pierced to create a starting point and yet still be cut at maximum speed. The only glass that can’t be cut is tempered glass, designed to shatter into tiny pieces if cut or broken. Stone The OMAX system can cut stone products of all types. Applications include granite countertops, quartz blanks for precision mirrors, inlaid marble flooring, decorative wall panels and stone sculptural pieces. Concrete Concrete cuts easily with the OMAX abrasivejet process and applications range from inlaid stepping stones to architectural features and sculptural panels. Ceramics Most ceramic materials can be cut with an OMAX abrasivejet. However if the hardness of the ceramic is greater than the hardness of garnet abrasive (between 7.5 and 8.5 on the Mohs scale), abrasivejet cutting will not be economically effective. Rubber Softer rubber and foam rubber cut easily using a water-only nozzle without abrasive. Fibre reinforced rubber and very hard rubber can be cut cleanly using the abrasivejet process. Complement Your Existing Manufacturing Process Re-think Your Cutting Solution Manufacturers from small job shops to large OEMs are finding that the OMAX abrasive waterjet cutting process is an ideal complement to their other manufacturing processes. In many cases the OMAX can quickly produce a complete final part, ready to go. However it can also produce a semi-finished or near-net-shape blank part suitable for secondary processing by conventional means. The abrasive waterjet process does not affect material properties, so the efficiency of conventional processes is not degraded. The close nesting capability of the OMAX maximises material utilisation. In addition, the OMAX is effective in many advanced and non-traditional materials where conventional processing may be a challenge. MillingShops often use OMAX systems as a complement to their traditional mills and vertical machining centres. The OMAX is ideal for making short-run two-dimensional parts on a quick-turnaround basis and does not required a skilled machinist or specialised programmer. In addition the OMAX can save material by quickly making closely-nested near-net-shape blanks in preparation for final machining. The fact that the OMAX abrasive waterjet process does not change material properties means that secondary machining can be carried out efficiently with conventional cutting tools. Wire EDM An OMAX system should not be viewed as a replacement for wire EDM, but rather as a complement. It is generally used by wire EDM shops to provide faster production where the ultra-high accuracy of wire EDM is not needed and to permit a shop to work with non-conductive materials such as composites and glass. It is also common to use an OMAX to produce a part to a general tolerance in the range of ±0.003″ to 0.005” (±75μ to 125μ) and then use wire EDM to finish off areas where greater accuracy is required. The OMAX can also be used to quickly pierce starting holes for the wire EDM process. Laser The key reason that laser shops and potential laser users buy an OMAX system is because it can work in a much wider variety of material and thicknesses. Advanced materials such as composites and laminates are easily cut on an OMAX, as are materials such as titanium or tool steel where the heat affected zone of a laser can be a problem. Thicker metals, such as aluminium, steel or stainless steel are also well-suited to the OMAX. It is common for laser specialty shops to purchase an OMAX simply to broaden their material capability. In addition an OMAX is typically one-third or less of the capital cost of a laser cutting system. This means that a shop that has been farming out work to a laser house can afford to buy an OMAX to bring the work in-house, thus saving money and improving scheduling and flexibility. It also means that a laser house can afford to purchase an OMAX to supplement their laser capability. Plasma Cutting As in the case of lasers, the key reason that plasma users buy an OMAX is because it can work in a much wider variety of materials and thicknesses. Plasma cutting generally results in a relatively large heat affected zone and is limited in the materials it can cut. The OMAX, on the other hand, can cut virtually any material over a wide range of thickness without any heat affected zone. Advanced materials such as composites and laminates are easily cut on an OMAX, as are heat-sensitive materials such as titanium or tool steel. It is becoming common to use a plasma for rapid cutting of large blanks and then to use an OMAX Waterjet for precision cutting of holes and features, as the waterjet is more accurate. Punch Press Shops generally purchase an OMAX to complement their traditional punch press when they need to work in a wider variety of material and thicknesses or need to make intricate shapes or closely-nested parts. Because of its very fast programming and set-up time, the OMAX is great for creating prototype parts and for short-run production. Service & Support Commitment Aquajet and OMAX are dedicated to be knowledgeable about your applications, expectations, and concerns. We pay attention to the smallest detail to insure your satisfaction, which is why 30% of our sales year after year are returning customers. Free factory training is included with your system to help you maximise the return on your investment. OMAX has the best ratio in the industry of service technicians to machines installed. This enables us to provide the quickest response time in the industry. A standard troubleshooting and application guide is included with every machine available free to our customer, which can facilitate even faster service response. The OMAX Interactive Reference Guide ( OIR ) comprised of over 3000 pages, covers every aspect of operating and maintaining your investment. It is unequalled for providing application solutions. The OIR is available to you 24 hours a day, seven days a week, including holidays, and is instantaneous to answer your questions. Applications Materials Waterjets can cut almost any material. Pure waterjets can quickly and accurately cut soft materials such as rubber, foam and other gasket material. Abrasive waterjets can cut almost any other material over a very wide range of thicknesses: Virtually all metals, including hardened tool steel, stainless steel, aluminium, copper and titanium Non-tempered glass, including multi-layer laminated safety glass Composites Laminates Stone Most ceramics Run Sizes Set-up time for a waterjet with an advanced control system is minimal. Advanced control software (such as the OMAX Intelli-MAX Software Suite) can automatically program the cutting path of a desired part directly from a CAD drawing. Just lightly secure the material stock to the cutting table and enter the material type and thickness into the control computer. The control system does the rest and an accurate part is produced on the first run. This capability makes waterjet a perfect process for short-run and one-off production parts. At the same time, modern nesting software means that waterjets are also ideal for mass production of parts with minimum waste. Table Sizes Waterjet cutting table are now available in a wide range of standard sizes, ranging from small 2’ 5” x 2’ 2” (737mm x 660mm) tables to very large 26’ 8” – 46’ 8” x 13’ 4” (8.1m – 14.2m x 4m) tables. The two considerations in selecting a table size are the size of part to be made and the size of stock material to be used. It is generally easiest and most economical to err on the side of a larger table that will handle all intended material stock sizes and future larger parts. However, sometimes space limitations mandate a smaller size. As a result of the design of our tables, OMAX offers the smallest footprint relative to the table size thereby conserving valuable shop floor space. Special Features Water cutting has some special characteristics that make it particularly attractive for some applications: Waterjets cut without heat. This means that there is no thermal distortion to complex and intricate parts and no heat affected zone that might change material properties. It also means that secondary machining processes, such as thread-tapping, are easily carried out on a waterjet-cut blank. Waterjets make a very narrow cut and have very low cutting forces. This frees part designers to create intricate parts that would be virtually impossible to make with conventional manufacturing processes. Very complex shapes and contours are easily possible with waterjet cutting. An additional benefit when expensive material is being machined is low waste costs. Advanced motion control permits production of precise parts. Traditional waterjets cut parts to a precision in the range of ±0.010” (0.25mm). However, by using mathematical models to account for and correct the natural error-creating curvature of a moving waterjet, modern high-precision waterjets with advanced control systems such as the OMAX Intelli-MAX Software Suite can make parts to a general tolerance of ±0.005” (±125μ). The most advanced systems have computer-controlled taper-compensation cutting heads and can control key part dimensions to an accuracy of ±0.001” (±25μ). Environmental Considerations Early waterjets had a well-earned reputation for being noisy and dirty. An exposed water jet is noisy and an exposed abrasive waterjet can throw a lot of abrasive dust into the air. However, these factors are eliminated in modern systems by simply cutting under a thin layer of water. The water layer reduces the noise level to below that of most machine tools and eliminates the dust by keeping the particulates in the water. An abrasive waterjet machine cutting under water can be placed anywhere that you might place a conventional machine tool. No noxious fumes or smoke is generated, and the part does not become contaminated with cutting oils. A waterjet machine generates two waste streams: Excess water containing very small amounts of solid fines, which can be filtered if required by local regulation and then sent directly to a waste water drain. Kerf material and garnet waste can be sent to a landfill. If the material being cut is poisonous—lead or beryllium, for example—both waste streams must be cleaned to meet environmental regulations and the water may be recycled. Aerospace manufacturing is a high technology industry that produces aircraft, guided missiles, space vehicles, aircraft engines, propulsion units, and related parts. Most of their part production is geared towards government work. Some examples of aerospace Original Equipment Manufacturers (OEMs) using OMAX waterjet technology include: custom control panels, structural components for special purpose aircraft, turbine blades, jet engines, aluminum skins, struts, brake components, nacelle components, and many other parts. Many areas of the medical industry operate an OMAX to develop items such as medical devices for patients, diagnosis, therapy, surgery, and prosthetics. Examples of OMAX application in this industry include: blanking out surgical instruments from special steel alloys; cutting artificial limb components from carbon fiber composites; manufacturing carbon braces and orthopedic appliances, and other products.