Home / Laser, Waterjet, Plasma Cutting Systems

Laser, Waterjet, Plasma Cutting Systems

A yearend review of some of the current advances and application capabilities in each of these metal cutting technologies.

Posted: November 5, 2014

An Eagle fiber laser cutting head with laser beam from MSS Lasers is one of the most advanced systems in the market, with linear drives on all three axes and a low inertia carbon fiber transverse bridge construction that can accelerate up to 6G with achieve cutting speeds in excess of 100 m/min.

Accuracy inside the Eagle fiber laser from MSS Lasers is assured through the rigidity of the carbon fiber bridge and the dynamic polymer concrete frame that minimizes vibration and heat related deflection of the machine geometry. With bed sizes up to 6 m x 2.5 m, this system increases material utilization by efficiently nesting jobs and cutting very large parts.

The SUPER TURBO-X laser-cutting system with Preview 3 control from Mazak Optonics uses proprietary vibration dampening frame and integrated laser resonator that ensure stable, high accuracy cutting of plates. The constant beam length construction provides uniform cutting performance across the machine table.

The TruLaser 8000 2D laser cutting machine from TRUMPF can process material up to 52 ft long and up to one inch thick using a 6 kW laser, making it ideal for processing very large parts or for job shops looking to expand their capacities and range of services.

KBM separate rotor and stator packages on ProLaser CL laser cutting systems from Proteck are supplied in kit form and directly mounted on the machine within their own bearing system and protective cover, with power and encoder connectors built-in. The mounting arrangement directly couples the large diameter pinion shaft to the rotor as a single solid assembly, restricting lost motion and potential unwanted harmonics that a flexible coupling may allow.

On ProLaser CL laser cutting systems from Proteck, S700 servo drives with multi-feedback capability from Kollmorgen are used with both resolver feedback, mounted on the KBM motor for commutation, and magnetic linear scales for the position loop. The feedback protocol is SSI absolute, EnDAT or alternatively BiSS, to suit a choice of CNC controllers with set-up and monitoring via EtherCAT that is integrated in all S700 drives.

With a maximum sheet size of 3.1 m x 1.6 m, next-generation ProLaser CL flat sheet cutting machines from Proteck also use AKM series rotary servo motors with Micron™ series planetary gearheads that are brake fitted for the Y-axis as well as the Z-axis.

The highly rigid MicroMAX JetMachining® Center from OMAX has a table size of 2 ft 4 in x 2 ft 4 in and an X-Y cutting travel of 2 ft x 2 ft. Its new Mini Tilt-A-Jet® cutting head nearly quadruples the position accuracy of the nozzle for even more precise cutting with virtually zero taper in most materials up to 3 in thick. The head is also 25 percent smaller and lighter and nearly twice as rigid for less deflection.

Intelli-MAX 21 for JetMachining Centers from OMAX not only optimizes tool paths automatically, it provides precise predictability of cutting speeds, taper, jet lag and other abrasivejet factors of those particular tool paths to achieve the highest levels of waterjet cutting speed and performance.

Supplied with a MAXJET 5i nozzle, the high precision A-Jet cutting head from OMAX cuts accurate beveled edges at angles determined by either the machine operator or part program. The A-Jet adds two motion axes, enabling the nozzle to tilt over a range of 0 deg to 60 deg from the vertical position. It can be used to easily produce beveled edges or cut countersunk holes, as well as machine parts with complex geometries. With its additional axes of motion, the A-Jet allows production of beveled edges in preparation for welding operations. The use of this accessory eliminates the need for many secondary machining and grinding operations.

With a Rotary Axis, JetMachining Centers from OMAX have up to 6-axis cutting capabilities that can create accurate complex 3D parts from pre-existing CAD drawings or DXF files. With the expanded parametric shape library, the Rotary Axis is ideal for pipe and tube cutting, simplifying challenging projects such as intersecting pipe fittings.

FlowXpert 2015 is a robust CAD/CAM software platform from Flow International that introduces significant new waterjet capabilities for 3D pathing and cutting that allow shops to work more effectively and with less complexity in 3D.

The DynaBeam laser height sensing technology from Flow maps the natural state of materials, reducing the need for manual adjustment throughout cutting. Operators can choose between setting the standoff height between the waterjet nozzle and the workpiece before every pierce, or pre-mapping an entire workpiece quickly and easily.

The price of a build-it-yourself WARDKit from WARDJet includes everything necessary to start waterjet cutting, including the tank, cutting head, grates, intensifier pump, control software, human machine interface and access to technical support. Upgrades and options on pump horsepower, controller style, and abrasive delivery system allow perfect configuration.

The Emerald 0606, the smallest waterjet ever manufactured by WARDJet, is designed to offer all the quality of a large, expensive waterjet cutting system at a reduced size and cost. Because of its rigid, sturdy tank design, the Emerald 0606 is capable of handling 12 in thick stainless steel just as easily as a 2 in sheet of foam.

The J-Series is a low-cost water-only waterjet from WARDJet that uses belt drive technology to cut at speeds of 2,500 ipm with an acceleration and deceleration rate of 0.2 m/s2. J-Series waterjets are ideal for cutting high volumes of parts where margins are low and tolerances are not as demanding.

The L-Series, the fastest cutting waterjet from WARDJet, uses a linear motion drive system with excellent accuracy, repeatability and reliability that cuts 7,000 ipm with an acceleration and deceleration rate of 1 sq m. The thick-walled steel tubing frame of the L-Series can accommodate multiple 5-axis cutting heads.

The FARM-JET waterjet cutting system from Jet Edge brings the power and versatility of ultra-high pressure waterjet cutting technology to farm machine shops for the price of a new fully loaded 1 ton 4X4 pickup truck, without requiring special electrical service.

The affordably priced direct-drive style Eco-Jet PTO ultra-high pressure waterjet pump is ideal for rural machine shops or areas with limited power because it utilizes a tractor PTO shaft to produce ultra-high pressure water for precision cutting, cleaning and surface preparation. It runs a .015 in waterjet orifice and can power most waterjet cutting systems and waterjet tools.

The economically priced BOSS-CUTTER water jet cutting system from Jet Edge is ideal for small shops. It has a 40 in x 40 in (1 m x 1m) work envelope with one abrasivejet cutting head and a motorized Z-axis with 5 in (513 mm) of travel that is controlled with a Windows PC (sold separately) and uses a FlashCut Pro-Series Stepper Controller and FlashCut CNC software. It also includes IGEMS path generation software and a hand-held controller pendant for operator convenience.

The compact SGX automated plasma and oxy-fuel cutting machine from ESAB features the easy-to-use Vision® T5 touch-screen CNC with built-in automatic nesting, as well as automatic gas controls and plasma automation powered by m3 Plasma technology. Performance and accuracy are assured with a heavy steel beam, precision machined mating surfaces, and linear rail. This rugged design ensures smooth motion, accuracy and long term machine durability. SGX enables higher productivity with rapid cut-to-cut cycle times through the integration of dual-side, high-speed AC drives and a fast torch lifter.

The do-it-yourself V Series Plasma from MultiCam features a custom-engineered, extruded aluminum frame with steel leg supports for high strength and rigidity. Automatic torch height is standard along with powerful, dual X-axis drive motors and Hypertherm PowerMax plasma torches. The easy-to-use, handheld operator interface features graphic icons for all machine functions.

The V-PRO CNC Plasma system from MultiCam has a standard, heavy-duty, all-steel water table with integrated bladder capable of production processing of sheet steel up to 1.25 in thick without the need for fume evacuation. The CNC plasma system uses a Hypertherm MAXPRO200 (200 amp) power supply engineered for heavy-duty, high capacity mechanized cutting.

The compact, durable 5-axis bevel plasma head from MultiCam uses aluminum castings for weight reduction and rigidity, has improved crash protection and ease of maintenance, and introduces the “phi” and “theta” axes of movement for cutting complex parts with bevels up to 45 deg in 2 in thick mild steel.

Designed to remove up to 25 lb of metal per hour, the PAK 200i manual gouging and plasma cutting system from Victor Thermal Dynamics can also hand cut 2 in thick mild steel at 10 ipm.

OMAX recently expanded its Intelli-MAX® Software Suite for JetMachining Centers with the release of Intelli-MAX 21, a new fourth generation cutting model that not only optimizes tool paths automatically, it gives users precise predictability as to cutting speeds, taper, jet lag and other abrasivejet factors of those particular tool paths. All of which takes abrasive waterjet cutting to the industry’s highest levels of speed and performance.

The cutting model within Intelli-MAX 21 builds upon years of real-world abrasive waterjet data accumulated through first and second-generation equation-based cutting models as well as from the massive data set of its third-generation model. The result is a cutting model that provides highly precise process and machine behavior predictions. Intelli-MAX Software updates bring performance enhancements to the company’s broad range of machine accessories. With version 21, Tilt-A-Jet users experience increased speed and accuracy when machining inside corners and small radii, especially in thick materials.

Based on customer feedback, Intelli-MAX 21 includes AutoPath command improvements, better import capabilities for DXF/DWG and PDF files, as well as enhanced memory for the 3D Path Editor. The software requires minimal operator training and makes it easy for users to create precision 2D and 3D parts faster and at a lower cost. “Whether it involves better file importing or expanding our parametric shape library for enhanced 3D cutting, we continuously update and improve our software so we can effectively support the diverse and changing needs of our customers,” said Carl Olsen, the lead software engineer for OMAX. “Intelli-MAX updates are free to machine owners for as long as they own their equipment.”

The company backs all Intelli-MAX Software updates with unparalleled support, continuously adding to and updating its software help screens, giving users access to more than 2,000 pages of tutorials, troubleshooting guides, videos, and tips and tricks, directly at the machine controller.

In related developments, OMAX and Spatial Corporation (Broomfield, CO), a leading provider of 3D development components for manufacturing applications, have combined their technologies to create what could be considered the market’s easiest-to-use 3D tool pathing solution. The Intelli-CAM™ software tool for JetMachining Centers generates 3D tool paths from solid 3D models as well as quickly performs 3D to 2D file conversions.

Intelli-CAM incorporates Spatial’s 3D InterOp to import CAD files from a variety of 3D sources, including CATIA, SolidWorks®, Solid Edge, Autodesk® Inventor®, Siemens® NX, Pro/E®, Creo® and much more. The software then applies custom solutions from OMAX and Spatial, such as the advanced AutoPath function or slice plane, to convert the geometry into full 3D paths suitable for waterjet cutting, ensuring the most precise part in the least amount of time and with minimal operator involvement.

With its user-friendly and powerful 2D conversion system, Intelli-CAM generates machine-ready cutting geometry through a few simple computer mouse clicks. With the 3D file imported, users extract the desired 2D profile directly from a slicing plane, shadow or face. Intuitive navigation tools make it easy for users to position and orient the slice – including rotations around all axes, orienting to a face, or projecting as a shadow.

Spatial’s 3D InterOp technology allows OMAX to provide extremely robust and proven 3D file import capabilities to JetMachining Center owners. “Our customers can now import practically any major 2D or 3D CAD drawing out there, which is especially beneficial to job shops because they often don’t know the original CAD system for a file,” says Olsen. “Plus, they don’t have to purchase expensive CAD software filter packages.”

Olsen also noted that customers doing 3D programming for 5-axis waterjet cutting will find Intelli-CAM greatly simplifies those operations, suggesting that it “may be the easiest to use 5-axis CAM software ever.” Intelli-CAM, which interfaces directly with the intuitive Intelli-MAX Software Suite, is available as a free update to JetMachining Center owners and is backed by the company’s unparalleled support.

Expanded taper control capabilities can be achieved through the popular A-Jet cutting head using the Intelli-MAX Software Suite for JetMachining Centers. A special feature within the intuitive software improves the performance of the A-Jet so it can make precise angled cuts and bevels and automatically correct for the taper normally found in an abrasive waterjet cut.

Programming for the A-Jet is largely automatic through the Intelli-MAX Software. Operators are able to choose the angle for part edges that require beveling, with cornering then handled automatically by the machine control. Operators also have a choice of piercing vertically to minimize splashing. With the new capabilities of the Intelli-MAX control software, operators can now choose between three types of taper compensation: full-control Manual compensation, quick Smart Taper compensation, and precise Intelli-TAPER® compensation. The A-Jet is designed to be retrofitable to existing machine models.

Several accessories are offered for JetMachining Centers to further increase their performance and versatility, including a Rotary Axis head that provides infinite rotation while cutting. The Rotary Axis is easy to program and has an expanded parametric shape library for enhanced 3D pipe cutting.

The accessory’s drive head allows for customized fixtures, and the versatile attachment design of the Rotary Axis enables users to position the head in various locations in the tank. Fully submersible and powered by common table controls, the rotary head does not require an additional power supply. The accessory also contains a built-in water drip sensor with warning lights and automatic shutdown. Additionally, the Rotary Axis is equipped with external grease fittings for easy maintenance.

OMAX designs and manufactures some of the world’s most advanced abrasive waterjet technology in a variety of table sizes and price points. Backed by unmatched support and powered by the company’s intuitive control software, OMAX and MAXIEM® JetMachining® Centers bring affordable performance to a continuously expanding range of industries.

OMAX Corporation, 21409 72nd Avenue South, Kent, WA 98032, 800-838-0343, sandra.mclain@omax.com, www.omax.com.

NEXT GENERATION SOFTWARE FOR FASTER, SMARTER PROGRAMMING
Flow International Corporation (Kent, WA), a leading developer and manufacturer of industrial waterjet machines for cutting and cleaning applications, has upgraded the FlowXpert™ Software Suite with FlowXpert 2015, which introduces significant new capabilities for 3D pathing and cutting which allow waterjet users to work more effectively in 3D, with less complexity.

FlowXpert 2015 is a robust 3D CAD/CAM software platform that expands on the 2D FlowMaster® intelligent Software Suite. The platform includes Design powered by Spaceclaim, an integrated 3D CAD/CAM programming tool with Flow Sequencer. With this release, the integrated CAD/CAM capabilities give users a seamless pathing experience. The integration with Flow Sequencer adds flexibility to users and is designed specifically for waterjet cutting, resulting in faster waterjet programming.

“By integrating these platforms we are providing users even greater flexibility in designing and pathing, which will have great benefits for both basic and complex waterjet parts,” explains Dr. Alex Chillman, the software and cutting platform manager at Flow. The software integration was engineered in partnership with Spaceclaim to take full advantage of Flow’s 40 years of waterjet application expertise and give users faster, smarter programming that is interactive. Incorporating best practices such as waterjet application tips, material cut speed knowledge, improved pathing algorithms and expanded lead in/out customization, the program estimates what steps are needed to get the best part.

The end result is a smarter, powerful, straightforward 3D system that lets users to do their work in fewer steps, with more intuitive design practices. The new FlowXpert 2015 includes functions familiar for current FlowXpert users, with a redesigned interface for intuitive 3D and 2D part programming. New capabilities in include:

Integration of CAD Design powered by Spaceclaim with CAM Flow Sequencer modules.
Waterjet specific geometry analysis means the part is ready faster.
3D CAM offset capabilities.
Custom lead in/out available; or choose from an expanded lead in/out catalogue.
Fast, versatile sheet metal processing from Spaceclaim.
Advanced clean up tools that can be customized to your waterjet.
Greater automation from smart pathing powered by Flow application expertise.
Save your 3D model as a 2D programmed part.

All of this means users can now design a part and path it in the same program. Modifying the geometry of a part is now possible without losing the path, and in most cases the Sequencer integration will automatically update the path to accommodate the changes; a feature strongly requested by customers. In addition, the software will now detect model and path errors and suggest fixes. FlowXpert 2015 will be available in early 2015 globally.

The company also offers the only non-contact material height sensing solution available in the industry, the DynaBeam™ Laser Sensing System. Exclusively from Flow, the DynaBeam provides superior accuracy to traditional height monitoring methods. “We are very excited to introduce the first non-contact precision height sensor to the waterjet industry,” said Dr. Mohamed Hashish, a senior vice president of technology at Flow. “With this advancement we continue to ensure that our customers have the most advanced tools for the highest productivity and accuracy of cut parts.”

Laser measuring is highly accurate without requiring physical contact with a material. The DynaBeam laser height sensing technology maps the natural state of materials, reducing the need for manual adjustment throughout cutting. Operators can choose between setting the standoff height between the waterjet nozzle and the workpiece before every pierce, or pre-mapping an entire workpiece quickly and easily. Used in combination with both Dynamic Waterjet® and Dynamic Waterjet XD for 2D and 3D bevel cutting the system ensures faster, more accurate waterjet cutting.

“The DynaBeam is a unique combination of waterjet cutting versatility and laser precision measuring capabilities,” adds Dr. Chillman. “Nozzle offset height can be set to an accuracy of ± 0.1 mm (0.004 in) very quickly.” This fast, accurate, non-contact method results in no scratches to the material. The laser ensures waterjet cutting to high precision; necessary when producing close tolerance, multi-axis parts. Operators can quickly and easily cut precise parts, even when bevel cutting.