WATERJETS FOR VERY LARGE SHEET SIZES

The Byjet L waterjet cutting system from Bystronic Inc. (Hauppauge, NY) is an abrasive waterjet cutting system optimized for the processing of large sheet sizes. The base frame of the machine is a modular construction that can be expanded in 6.5 ft increments based upon the end-user?s needs.

Models offered range from the Byjet L 2030 with a 6.5 ft x 10 ft cutting area up to the Byjet L 16030 with a 52.5 ft x 10 ft cutting area. All models include two High Precision Technology (HPT) abrasive waterjet cutting heads with automatic head spacing, height sensing and collision protection on each cutting head. Optional third and fourth cutting heads are available for even higher productivity.

?The Byjet L offers an impressive combination of precision and production while also reducing the user?s cost per part by minimizing abrasive, electric and water consumption,? states Frank Arteaga, head of product management for the market region NAFTA. ?The use of two or more cutting heads does wonders in the absorption of overhead and labor costs.?

Output of the systems is enhanced even further by the use of removable cassettes that allow for quick loading and unloading of material. Options for abrasive removal and water leveling are also available. The use of bulk abrasive bags is facilitated by the bulk bag extension kit, allowing the machine to run uninterrupted for longer periods of time without the need for abrasive replenishment.

The Bysoft CADCAM software package is included with the system and optimizes nesting for multi-head waterjet cutting. The ByVision control provides a clean, easy-to-use interface for the operator in a Windows-based environment.

All of the Byjet L systems use the Bypump 50 APC (Active Pressure Control) intensifier pump, which cuts faster at a lower operating cost because of its unique dual cylinder intensifier design. With CNC control for each of the cylinders, Bypump 50 APC is able to maintain a constant pressure without the need for a large, costly pressure accumulator. Maintaining a constant pressure allows the Bypump 50 APC to cut at faster speeds and with less abrasive.

The Bypump 50 APC outputs 1.3 gpm of water, which allows either one head cutting with a 0.016 in orifice, or two heads with 0.011 in orifices. The high water output allows for economical cutting with two cutting heads, while saving electricity versus using a costlier 100 hp pump. If more than two cutting heads are required, additional pumps can be added in series, allowing the benefit of redundancy; if one pump is off-line for maintenance, the other pump can still be producing parts.

From a maintenance standpoint, the simple design of the intensifier makes for quick and easy seal changes. All components within the pump are easily accessible. Diagnostics within the pump control allow for monitoring over 20 signals to make troubleshooting easier. These diagnostics signals can be accessed either at the pump itself, or through the Byvision control.

CNC-controlled abrasive metering is now offered on all Byjet abrasive waterjet cutting systems. This system allows for the fine tuning of the amount of abrasive to be used. On the fly, abrasive amount can be changed anywhere from zero to 1.5 lb per minute. Having this ability allows the Byjet to use less abrasive when applications require a smoother edge and more abrasive when maximum speed is desired.

Cost per part is reduced by using less abrasive during the piercing cycle. Abrasive consumption can typically be reduced by approximately 50 percent during the piercing time. Consumable parts cost is reduced since the abrasive nozzle wear is minimized by optimizing the amount of abrasive that is going through the nozzle at any point in time. ?When you look at the amount of time it takes to pierce thicker material with a waterjet and the number of pierces that a waterjet will do during the day, the cost savings from reducing your abrasive amount during that piercing time are significant,? observes Jeff Day, product manager of waterjets.

One of the side-benefits of CNC-abrasive metering, in conjunction with the Bypump 50 APC?s ability to change pressure on the fly, is the opportunity to use etching for part identification, or for layout markings for downstream operations. This can help to reduce the overall cost of a finished assembly. Further cost savings are realized at both the ?abrasive in? and ?abrasive out? ends of the waterjet manufacturing cycle. Less abrasive used means fewer man-hours per day putting new abrasive into the machine?s abrasive hopper. When it comes time to dispose of the used abrasive, the cost of abrasive disposal is also reduced.

The new Manual Bevel Angle cutting head option for Byjet waterjet cutting systems increases the flexibility of the system by allowing cutting at up to a 45 deg angle. In conjunction with the integrated height control and collision protection, the bevel head can be used for weld preparation or the cutting of holes that must be at an angle to the plate. ?This option is just another innovative way of looking at waterjet cutting,? observes Day. ?With the increased demand for perforated armor plate for military applications, this option couldn?t have become available at a better time.?

Most perforated armor plate for military applications (MIL-PRF-32269) utilizes rounded slots, but this geometry is not fixed. What is important is weight reduction and maintaining the angle of the holes. Casting techniques have been used in the past for this application. Now, using waterjet allows the end-user to offer flexibility in design.

Day explains, ?If a military application comes along and the customer wants square slots instead of rounded slots, or whatever other geometry, with waterjet cutting, you can just program the desired geometry. You don?t have to make up a die set and then multiple molds to get to the end product. While doing this type of cutting with one cutting head may not be productive enough, having a system with multiple cutting heads like this starts to make economic sense.?

This manual bevel head option is available on new Byjet machines or can be retrofitted to existing machines. Current users interested in the option should contact Bystronic for further information.

Bystronic Inc. has offered customers single source service expertise for over 30 years. They provide innovative laser cutting, waterjet cutting and press brake systems, system software and comprehensive customer training and support. The company?s North American headquarters is located in Hauppauge, with other offices in Chicago, Los Angeles, Toronto, Canada and Guadalajara, Mexico.

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Contact Frank Arteaga at sales.us@bystronic.om , 631-231-1212, www.bystronicusa.com