[Waterjet Processing Applications] Waterjet processing solves the material cutting challenges of quality control and greatly improves production efficiency!
Quality assurance and quality control are essential processes in factory production. Regardless of how long production takes place in the factory, regular quality checks must be performed to maintain consistent quality levels. Quality control on the production line typically involves periodically testing produced samples, and most importantly, these samples must originate from the production line.
By definition, a sample without a substitute is valid; otherwise, it is not a "sample." Quality control processes may involve testing raw materials to verify material properties, testing manufacturing steps to ensure they are performed correctly, and inspecting finished products to ensure conformity.
In quality control applications, samples must be physically cut to prepare for testing. Quality control engineers face several challenges when designing these sample cutting procedures. First is speed; samples must be produced quickly because online quality checks can delay a production batch. Second, features may not be easily visible when visual inspection is required. Finally, cutting samples from materials or production lines may alter the integrity of the material when preparing them for quality control testing.
By definition, a sample without a substitute is valid; otherwise, it is not a "sample." Quality control processes may involve testing raw materials to verify material properties, testing manufacturing steps to ensure they are performed correctly, and inspecting finished products to ensure conformity.
In quality control applications, samples must be physically cut to prepare for testing. Quality control engineers face several challenges when designing these sample cutting procedures. First is speed; samples must be produced quickly because online quality checks can delay a production batch. Second, features may not be easily visible when visual inspection is required. Finally, cutting samples from materials or production lines may alter the integrity of the material when preparing them for quality control testing.
There are various cutting methods, but each method has its limitations.
While there are various methods for cutting samples, each presents different challenges for quality control. Currently, there are many ways to cut metal, but each method is generally limited to certain types of metal. Traditional machining is mainly used for metal blanks, such as shearing for metal sheets, laser cutting for non-reflective metal sheets, and plasma cutting for thick, conductive metal sheets.
For non-metallic materials, there are even fewer practical cutting techniques. Fiber composites produce toxic dust when cut with a saw or rotary blade, while ceramics can crack or shatter, even when cut with a special wet saw. Plastics and rubber materials may melt, glue, or emit fumes when cut with a blade or laser .
Worse still, these cutting methods often cause material deformation during the process. Laser cutting produces a heat-affected reaction, hardening the cut edges. Sawing or shearing can cause the edges of the sheet material to bend or deform, and the heat introduced by plasma cutting can deform thin materials. Therefore, each of these cutting techniques affects the results of quality control.
Fortunately, there is a cutting process suitable for all materials while minimizing deformation of the material being cut: abrasive waterjet cutting . Waterjet cutting combines a narrow stream of high-pressure water with abrasive particles, spraying the slurry through a nozzle to penetrate the object. This is a micro-corrosion material removal process that can cut without generating heat or mechanical stress on the material. Since all materials corrode, waterjet cutting is often preferable, leaving a smooth surface finish similar to sandblasting.
Waterjet cutting technology is particularly suitable for quality control applications that require ensuring the integrity of materials or parts. However, quality control departments often struggle to justify the capital investment in large waterjet cutting machines until recently, when smaller models became available. Newly released and affordable waterjet cutting machines allow quality control engineers to use this unique technology to quickly cut precise samples of materials for internal use.
For non-metallic materials, there are even fewer practical cutting techniques. Fiber composites produce toxic dust when cut with a saw or rotary blade, while ceramics can crack or shatter, even when cut with a special wet saw. Plastics and rubber materials may melt, glue, or emit fumes when cut with a blade or laser .
Worse still, these cutting methods often cause material deformation during the process. Laser cutting produces a heat-affected reaction, hardening the cut edges. Sawing or shearing can cause the edges of the sheet material to bend or deform, and the heat introduced by plasma cutting can deform thin materials. Therefore, each of these cutting techniques affects the results of quality control.
Fortunately, there is a cutting process suitable for all materials while minimizing deformation of the material being cut: abrasive waterjet cutting . Waterjet cutting combines a narrow stream of high-pressure water with abrasive particles, spraying the slurry through a nozzle to penetrate the object. This is a micro-corrosion material removal process that can cut without generating heat or mechanical stress on the material. Since all materials corrode, waterjet cutting is often preferable, leaving a smooth surface finish similar to sandblasting.
Waterjet cutting technology is particularly suitable for quality control applications that require ensuring the integrity of materials or parts. However, quality control departments often struggle to justify the capital investment in large waterjet cutting machines until recently, when smaller models became available. Newly released and affordable waterjet cutting machines allow quality control engineers to use this unique technology to quickly cut precise samples of materials for internal use.
Affordable waterjet cutting machines can be used for internal quality control applications.
Incorporating water jet technology into quality control processes
Consider an automotive supplier performing laser welding operations to join thin steel components. Weld samples from each production line batch must be inspected to verify the integrity of the entire batch of welds. How is the weld visually inspected? During the cutting process, the weld's cross-section must be cut through without distorting its integrity. Excessive heat cannot be introduced during cutting, therefore laser cutting , plasma cutting, or the use of angle grinders cannot be performed. Therefore, samples are typically hand-cut using a band saw. Even Tier 1 automotive suppliers hand-cut weld samples with a band saw on the production line for quality control.
Waterjet cutting technology is well-suited for solving this problem because it does not heat the weld during cutting , nor does it shear or otherwise distort it. The original shape of the weld is preserved, making it easy to inspect the weld cross-section.
The cross-section of the laser-welded joint is made visible through water jet cutting.
When evaluating thin-sheet stamped metal parts, quality control engineers face the challenge of preparing samples without damaging them. For example, an aluminum can manufacturer must inspect the top and bottom ("can") of the can after stamping to ensure the correct formation of the ridges. As part of a quality control process, samples on the production line must be inspected periodically. To inspect the cross-section, the can must be cut vertically in half. How can a stamped sheet of thin aluminum be cut without damaging the can's stamped shape and ridges? The answer is: embed the can in epoxy resin. The can is embedded in the epoxy resin, allowed to cure, and then the can is cut open with a band saw to remove the epoxy resin.
However, this time-consuming process delays the collection of QA data, which may further delay the identification and remediation of related production defects. A faster, simpler, and more consistent solution is now available: waterjet cutting machines . These can shear thin metals without deforming them due to excessive heat.
For quality control engineers at aerospace companies who must verify the properties of raw materials, using a waterjet cutter to cut tensile specimens is a smart choice. Hardened steel, a material produced through quenching and tempering, is tedious to cut using traditional methods due to rapid tool wear. Companies typically outsource this work to waterjet cutting services because they cannot afford traditional large equipment internally. Relying on external suppliers for critical quality control procedures can lead to delays and pose risks. Using a cost-effective, small waterjet cutter can significantly reduce these risks and allow the quality management department to control the entire production process.
However, this time-consuming process delays the collection of QA data, which may further delay the identification and remediation of related production defects. A faster, simpler, and more consistent solution is now available: waterjet cutting machines . These can shear thin metals without deforming them due to excessive heat.
For quality control engineers at aerospace companies who must verify the properties of raw materials, using a waterjet cutter to cut tensile specimens is a smart choice. Hardened steel, a material produced through quenching and tempering, is tedious to cut using traditional methods due to rapid tool wear. Companies typically outsource this work to waterjet cutting services because they cannot afford traditional large equipment internally. Relying on external suppliers for critical quality control procedures can lead to delays and pose risks. Using a cost-effective, small waterjet cutter can significantly reduce these risks and allow the quality management department to control the entire production process.
Hardened steel tensile specimens were cut internally using a waterjet cutter.
Accelerate the development of new materials
Material testing and quality assessment aren't confined to the production line. They're an integral part of a materials company's product development process. For example, a polyurethane materials manufacturer needs to test samples for each new formulation to evaluate material quality. While waterjet cutting of tensile specimens is already in use, the actual cutting work has to be outsourced to waterjet cutting services. Current waterjet cutting equipment is large and expensive, suitable only for high-volume production environments. Small materials companies' R&D departments simply can't afford one. Furthermore, the lead time before samples are returned is at least 2-3 weeks, severely delaying the entire testing process and disrupting subsequent verification schedules. With the advent of small waterjet cutting machines , materials manufacturers of any size can now perform material sample cutting in-house, shortening verification cycles, accelerating product development, and maintaining complete control over QA/QC processes.
Innovative waterjet technology controls quality
Waterjet cutting has always been relevant to the manufacturing process, and its advantages in quality control are obvious. Unlike test samples produced using laser , plasma, or traditional processing methods, waterjet cutting provides clean, readily inspectable samples while preserving the original characteristics of the material, such as welds and shape, like in canned goods. Furthermore, waterjet cutting machines are now smaller, more cost-effective, and easier to use. Therefore, quality control engineers can operate them readily within the company, whether in production, testing, or development. This significantly accelerates testing cycles and improves the completeness of quality control documentation.
Material testing and quality assessment aren't confined to the production line. They're an integral part of a materials company's product development process. For example, a polyurethane materials manufacturer needs to test samples for each new formulation to evaluate material quality. While waterjet cutting of tensile specimens is already in use, the actual cutting work has to be outsourced to waterjet cutting services. Current waterjet cutting equipment is large and expensive, suitable only for high-volume production environments. Small materials companies' R&D departments simply can't afford one. Furthermore, the lead time before samples are returned is at least 2-3 weeks, severely delaying the entire testing process and disrupting subsequent verification schedules. With the advent of small waterjet cutting machines , materials manufacturers of any size can now perform material sample cutting in-house, shortening verification cycles, accelerating product development, and maintaining complete control over QA/QC processes.
Innovative waterjet technology controls quality
Waterjet cutting has always been relevant to the manufacturing process, and its advantages in quality control are obvious. Unlike test samples produced using laser , plasma, or traditional processing methods, waterjet cutting provides clean, readily inspectable samples while preserving the original characteristics of the material, such as welds and shape, like in canned goods. Furthermore, waterjet cutting machines are now smaller, more cost-effective, and easier to use. Therefore, quality control engineers can operate them readily within the company, whether in production, testing, or development. This significantly accelerates testing cycles and improves the completeness of quality control documentation.
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