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Waterjet Cutting in Metal Fabrication

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Waterjet cutting is an innovative technology that has revolutionized metal fabrication and other industries. It involves using a high-pressure jet of water to cut through various materials including metals, plastics, and composites. Depending on the application, abrasive particles can be added to the water jet stream to further enhance the cutting ability. Waterjet cutting has become a popular choice in metal cutting because it offers a wide range of benefits compared to other metal cutting methods such as plasma cutting and laser cutting. In this blog post, we will discuss how waterjet cutting works and its advantages in metal fabrication.

How Does Waterjet Cutting Work?

Waterjet cutting involves a series of processes that include:

  1. Material preparation: This involves cleaning and drying the material to remove any debris or contaminants that could impede the cutting process.
  2. Design: The material is then designed using computer-aided design software (CAD). The CAD software generates a file that contains the exact design of the material to be cut.
  3. Programming: The CAD file is then transferred to a waterjet cutting machine that is programmed to follow the design specifications.
  4. Cutting: The waterjet machine cuts the material by directing a high-pressure jet of water through a small nozzle at the material. The force of the water cuts through the material, creating a clean and precise cut.

Advantages in Metal Fabrication

  1. Precise cuts: Waterjet cutting is a highly precise cutting method that can achieve a cut accuracy of up to 0.005 inches. This precision is due to its ability to produce a narrow and powerful cutting stream. This precision is essential in metal fabrication since it helps in creating parts with tight tolerances.
  2. Versatility: Waterjet cutting can cut through a wide range of materials, including metals, plastics, and composites. This versatility makes it a popular choice for metal fabrication, especially for materials that are difficult to cut using traditional cutting methods.
  3. Decreased material waste: Waterjet cutting generates reduced waste or scrap compared to other cutting methods. This is because the cutting process is very precise, and the kerf (the width of the cutting stream) is very narrow. This results in less material waste and reduced material costs.
  4. No Heat Affected Zone (HAZ): Other cutting methods such as plasma and laser cutting use heat to cut through materials. This heat can cause the material to warp, distort, or change its characteristics, leading to a HAZ. With waterjet cutting, there is no heat used in the cutting process, meaning that there is no HAZ.
  5. Eco-friendly: Waterjet cutting is eco-friendly compared to other cutting methods. This is because it does not generate any hazardous gases or dust, and it reduces water and energy consumption.

Applications in Metal Fabrication

Waterjet cutting has a wide range of applications in metal fabrication, including:

  1. Aerospace: The aerospace industry uses waterjet cutting in the fabrication of airplane parts such as wings, engine parts, and landing gears.
  2. Automotive: Waterjet cutting is used in the fabrication of automotive components such as body panels, exhaust systems, and engine parts.
  3. Architectural Metalwork: Waterjet cutting is used to create architectural metalwork such as railings, stairs, and decorative metal features in buildings.
  4. Medical Devices: Waterjet cutting is used in the fabrication of devices in the medical industry such as surgical instruments, prosthetics, and orthopaedic implants.
  5. Industrial Machinery: Waterjet cutting is used in the fabrication of industrial machinery such as pumps, valves, pressure vessels and gears.

Closing Comments

Waterjet cutting has become a popular choice in structural steel fabrication due to its precision, versatility, and eco-friendliness. It offers several benefits compared to other cutting methods and has a wide range of applications in various industries. Its precision and ability to cut through difficult to cut materials make it a valuable tool in metal fabrication.

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How to Reduce Laser Cutting Costs – Part II

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As discussed in the first part of the blog on reducing laser cutting costs, laser cutting production fits particular specifications and accurately delivers a piece’s details the first time. Many companies, small businesses, and industrial organizations tend to choose laser cutting because it produces barely perceptible edge effects from the cutting, unlike many other methods. Versatility in size and metal material is another benefit of laser cutting machinery, although these do have differences in price. In this blog, other means of diminishing expenses while using this incredible technology will be covered along with relevant considerations in this regard.

Creating Prototypes

Constructing a prototype of the fabrication design digitally, on paper or with a sturdier disposable material helps to develop a clear vision of the final product. The appearance of the design will be easier to tweak or simplify once there is a mock-up involved. Ordering the full quantity of a laser cut product without refining the desired outcome is ineffective and drains the company bank account when another order is to be placed. It is good practice to print the design from a computer onto paper with the correct measurements and spacing between the two-dimensional shapes to examine the problematic points that might cost more money in production. Digital models can also be useful since the capabilities of design software can be used to alter small-scale issues. Performing this preliminary test by heavy steel fabrication companies increases confidence in the result and reduces any costs working out kinks that are caught early.

Placing a Small Order

Once the simplified design and idea for the material have been confirmed, a small trial run of the exact supplies and design can reduce extra expenses before placing a substantial order. If certain aspects of the design are still unclear or testing of multiple metals is required, small orders will present the possibilities of several kinds of metal and the accurate implementation of your design. Any complications that arise in a small trial order will cost less than purchasing several big sheets of metal and then realizing that the specifications should have been different. Once it is evident that this metal is the fit for your intentions, the complete order can follow the small order.

Outsourcing Laser Cutting

When a project requires a precise cut that only laser cutting can accomplish, a do-it-yourself direction may be the first impulse. However, on-site laser cutting involves expensive investments in mining plant and equipment, thorough training, and inconvenient maintenance. Rather than mastering laser cutting and facing these obstacles, it is more cost-effective to outsource to experienced companies. Since laser cutting is an important fabrication technique, the equipment is substantial in size and cost. Purchasing laser cutting machinery, depending on the size and nature of your company, will likely not be reused enough to cover the costs. Necessary on-site space is infringed on, and employee training also halts the production process.

Using a specialized outside team to perform the work saves space, time, and money. The machinery also demands regular upkeep, which raises costs even higher. Safety for the work space and the condition of the products require this maintenance, but the drawbacks of further expense, repairs and effort point to another solution — outsourcing. Enlisting the help of workers skilled in this area will expedite the project and reduce overheads. They are familiar with the best practices in laser cutting, already knowledgeable about this task and able to maintain the equipment elsewhere.

Final Thoughts

Cutting down on production time and increasing intentionality in design files will reduce the cost of custom-cut pieces. Adjusting the orientation of the design if multiple pieces are manufactured will also diminish wasted metal and extra time. Overall, these techniques have the potential to ensure that the project should be finished sooner than ever before at a lower price. Hence, cutting is the way to go – for both laser and costs!

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How to Reduce Laser Cutting Costs – Part I

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Metal cutting is an important operation in most fabrication projects and laser cutting is preferred in many sectors. The precisely cut two-dimensional pieces function as machinery parts in industries from industrial baking to medicine. A common criticism of laser cutting is the cost involved during production, which can be quite high in many cases. However, many companies are unaware that their laser cutting costs, despite the production, could be significantly reduced by simple, alternate choices and communication with their laser cutting provider. So, how can the cost of laser cutting be reduced without compromising on the quality of the end deliverable? The first part of this two-part blog will focus on two techniques while looking to answer this and other questions.

Consider Sheet Metal Type and Thickness

A variety of metals can be cut, including mild steel, stainless steel, aluminum, copper, and brass. The thickness of the selected metal can alter the edge quality of the cuts, but most importantly the thickness of the metal determines how quickly the beam can cut or change due to heat induction bending services. Each of these metals has an optimal cutting thickness that displays the most stable and untainted cut possible with minimal warping or variation. If a thicker or denser metal is selected, then the time spent by the laser cutting company on the design will increase. If that metal is necessary for the project, a thick metal paired with a simple design may balance out the cost. It is important to prioritize the factors that are most important to the company and the productivity of the fabrication task in many cases.

Optimize Space by Grouping and Nesting

Laser cutting carves lines on sheet metal that are often spread out, with similar design elements and edges. However, eliminating empty segments in the design file dramatically diminishes the cost, in a similar way to avoiding double cut lines. It is efficient to reduce waste and scrap metal by increasing the usable portions of the sheet of metal. Filling the whole sheet of metal with the desired product is the ideal outcome. Wasting minuscule scrapings and debris is an inevitability most of the time, but more substantial portions of scrap metal can become profitable for the organization. Grouping and nesting are two variations of this principle.

Grouping the pieces just clusters them for efficient laser work. In general, the less distance the laser head must travel to make the next cut and the less scrap metal produced will keep more money in your pocket. This method is a simple way to create more space on the sheet of metal, and it accommodates circular cuts more easily than nesting does. Rounded lines, while expensive, may be necessary for the metal fabrication work. Positioning the shapes as close to one another as possible will be cost effective. Nesting is a more specific technique to reduce waste. This method rearranges the pieces to be cut so that they share common edges and create little excess space for optimal shapes. When complementary lines are placed together, the edge of two different shapes becomes one affordable slice. Nesting is another reason why finding the straightest lines for desired products (e.g., I-beams in structural construction) should be a priority because exact lines and angles are more likely to coincide for a common edge.

Summing Up

Laser cutting is a very technical process and it is important to understand which cost saving approach is a best-fit for a metal fabrication engagement. Understanding the types of metal used and characteristics of laser cutting deliverables helps in devising more effective cost saving strategies. While these methods are useful in the context of laser cutting jobs, there are other cost-saving techniques in laser cutting which will be discussed.

Plasma cutting of work pieces of steel structures from heavy steel plate

Laser Cutting vs. Plasma Cutting

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There are many factors which determine the metal cutting process to be used in fabrication projects such as, budget, timeline, costs, production rates, precision levels, and methods of configuring parts. In this regard, laser cutting and plasma cutting stand out as effective solutions for a range of industries. Laser cutting is a process that uses a highly concentrated, intense pulsed or continuous beam of light to cut various metals while plasma cutting uses a melting technique to deliver precise work (e.g., water tanks). So, what are the considerations to be kept in mind when choosing the best cutting method? We will look to dive deeper into this topic.

Overview of Laser and Plasma Cutting

Laser cutting utilizes laser optics and the use of computer numerical control (CNC) to heat and melt the metal while partially vaporizing it. It creates pristine, accurate cuts and works with a range of metals. This technique is often used for various industrial manufacturing applications such as manufacturing pressure vessels, as well as for engraving details, creating intricate notches, and cutting small shapes. Laser cutting is especially useful in cases when the products require precision, whether it is a complex or simple part. Advantages of laser cutting include cutting a wider variety of metals, having a standard tolerance of +/- 0.005″ and being equipped to cut thinner, more intricate metals.

In Plasma cutting, ionized gas, also known as plasma, melts the metal and then expels it. Essentially, compressed air and inert gasses like nitrogen and hydrogen shoot through a nozzle at extreme speeds to essentially blast metals such as stainless steel, copper, aluminum, steel, brass, and others with plasma. This cutting process supports applications like automotive repair, industrial construction, and hopper and tank fabrication, among others.

Choosing the Right Cutting Method

Working with a plasma cutting machine vs. a laser cutting machine can produce different solutions depending on many factors, two of which are the type and thickness of the metal. Some considerations involved when choosing the best cutting method are as follows: –

  • Cut edge quality: The quality of a part’s cut edge refers to the squareness of a product’s finished borders. Laser cutting creates a square cut while plasma cutting results in a lower edge quality level, as it is beveled.
  • Cut part precision: This precision depends on many aspects, such as heat distortion and the kerf width, as well as the size of the part vs. its programmed size. Laser cutting creates better part precision compared to the plasma technique, hence it adds value as part of custom metal fabrication techniques.
  • Cost: The cost of laser vs. plasma metal cutting takes factors such as power, abrasives, gases, consumables, and maintenance into consideration. While plasma cutting is often more cost-effective, the laser technique is faster if thick metals are not being used.
  • Production rate: The time taken to cut the metal should also be considered. Plasma cutting will be more efficient with thicker metals, while the laser method is faster and more precise with thinner resources.
  • Metal thickness: Laser cutters can cut metals up to 1 inch thick, while plasma can cut up to 5 inches or more.

The Verdict

Laser cutting is a superior option to plasma cutting when direct comparisons are made regarding precision, flexibility, production, edge quality and metal thickness. Understanding how a plasma cutting machine works compared to the laser technique indicates that the latter can help produce products with better precision and quality irrespective of the type of metal. Though laser cutting can be more expensive, it provides a lot of freedom to businesses and is the preferred cutting method of industries!

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Sheet Metal Defects and Solutions – Part II

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Continuing from the first blog, the second part of this two-blog series will continue to discuss defects arising from common fabrication processes – in this case, metal cutting/shearing and stamping – and how to ensure that these issues are ironed out as part of overall effort to ensure that the end product is of the highest quality. As we will see going forward, there are some common themes which give rise to imperfections during the manufacturing process. These defects can be caused by incorrect material choice, poor tooling and improper operating procedures among other reasons. Let’s dive in and have a closer look at this fascinating topic.

Cutting/Shearing Defects and Solutions

Sheet metal cutting refers to the application of a significant force on the sheet which eventually causes it to break into parts. The most common method of cutting is by shearing, in which a shearing force greater than the ultimate shear strength of the material is applied, causing it to fail and separate at that location.

Burred and Deformed Edges – Burred edges are sharp, uneven metal pieces that remain attached to a sheared metal workpiece. They usually arise due to blunt blades, or improper positioning thereof. Similarly, deformed edges are formed due to faulty clamp pressures, in addition to the improper positioning of blades. To prevent this, the shear machine’s manual can be referred to obtain the correct clearance and clamp pressure according to the material type and thickness.

Twisting – After completing a shearing process, the metal may have experienced some twisting along its axis. This is caused by cutting too narrow strips or using the incorrect rake angle. This can be avoided by adjusting the rake angle depending on the sheet metal’s properties, geometry, and cutting parameters.

Cambering – Cambering is observed when the sheet metal workpiece has a varying thickness along its width. This occurs when it moves in a horizontal direction, but without twisting or lifting along its edges. The result is a concave, convex, and triangular-shaped metal. This defect can be minimized early on by shifting the direction of the metal grains, and by changing the rake angle.

Stamping Defects and Solutions

The sheet metal stamping process is a cold-forming steel fabrication process where a die is used on a press machine to punch an impression on a metallic blank shape, thus forming plastic deformation. This process may also be accompanied by other forming tools to obtain a completed piece or as an intermediate step.

Splits – Sometimes when the metal layers are pushed past their workability limits, they start to thin until the flat layer tears along the weakest area. Such defects are known as ‘necking’ or ‘splitting’ in the sheet metal stamping process. To ensure this does not occur, forming simulation software should be used to analyze the sheet before the operation is started.

Wrinkles – When the compressive strain conditions applied by the processing equipment push the sheet metal upon itself, the linear force is crushed inwards until a wrinkled flange is obtained and the internal geometry is damaged. Such defects can be countered by stretching or drawing the sheets instead of forming them.

Springback – When the bend radius falls below the set value imposed by the heat induction bending equipment, the desired shape is not achieved. This is known as spring back, or final part deviation due to an incorrect process. To correct these defects, it is recommended to include an overbend or overcompensation adjustment.

Signing Off

Apart from sheet metal forming processes, other common errors can occur during the manufacturing process. For instance, some of the common defects include surface scratches, contamination, dents, and pinholes. Sometimes, controlling these defects can be difficult, and often requires special attention during the process. However, it is commonly agreed that in case of defects, reworking instead of replacing is the way to go – as it saves on two major metrics, cost and time!

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Custom Metal Fabrication Techniques for Value Addition

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Standard fabrication projects are widely prevalent, however in many instances, metal fabrication projects are customized to increase the value of a solution. Every custom metal fabrication project inevitably begins with research, in order to assess the appropriate materials and methods to cost-effectively produce each unique fabrication design. From design to delivery, the custom metal fabrication process is designed to produce more durable, quality results that deliver long-term value, an example being fabrication of parts of battery electric vehicles. So, how is the customization achieved and what techniques are used to produce higher-quality fabrications with long-term value? This blog will look to delve deeper in this subject.

Establishing Design Intent

The design of a metal fabrication project is critical for reaching the desired outcome, which is added value. A full-service fabricator can take a standard plan or an engineering drawing to flush out a detailed design that will accomplish the desired results for even the most complex project. This may require refining and testing the design per industry-specific requirements or regulations and identifying all the required components to serve as the building blocks for the final project.

Metal Cutting and Forming

Prior to the start of the cutting process, the metal fabricator must assess what type of method is appropriate for the metal type and thickness. Laser cutting is an effective choice for delicate metal fabrications or for heavy steel plates that demand tight tolerances. On the other hand, lasers are not ideal for metal composites or materials that have impurities. Forming the metal may require different sheet metal fabrication techniques like bending, plate and angle rolling or punching. It is crucial to select the right machinery to deliver the desired result. Metal forming success is based on selecting the correct machinery to perform the task. A full-service metal fabricator will likely have the necessary equipment in house, which can save both time and resources.

Custom Welding and Assembling

Custom welding and assembly techniques can guarantee that each project meets specific industry standards. A custom fabricator featuring certified welders and a strong quality control program is more likely to meet the industry requirements that add value. If you’re considering a partnership with heavy steel fabrication companies, be sure to ask for documentation of welder certifications. Beyond that, all assemblies and subassemblies should be tested together to ensure the final fabrication project functions as intended. Ideally, the entire assembly process should be documented as part of a fabricators structured quality control practices.

Expert Finishing

Finishing is the final step in preparing metal products for use, a crucial component for any metal fabrication project. Finishing helps to make products more resistant to corrosion, while providing higher electrical, chemical or tarnish resistance. Beyond that, finishing adds additional durability and makes metal surfaces look their best. For most projects, a product’s finish is determined by its intended use. Metal finishing encompasses more than one process, so it can be executed in multiple ways. Finishing would be dependent on alignment of process to product usage, cost-effectiveness and suitability of project materials.

Finishing Touches

To ensure that customized fabrication does not adversely impact project timelines, fabrication components should be shipped in their most complete form possible, while larger projects should be shipped with large subassemblies that can be assembled quickly upon arrival. Products developed using customized fabrication are expected to increase in demand as part of more complex client requirements, for instance mining plant and equipment needs to be customized regularly. This would give opportunities for fabricators to put their creativity to good use – however providing value remains paramount and, since the customer is king, value should be at the forefront of all services in this regard!

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Steel Laser Cutting – Versatility in Industry

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Cutting and manipulating various forms of metal is one of the sheet metal fabrication techniques and is used in industries such as manufacturing, fabrication, construction etc. However, there has been an increased focus on ensuring precision and flexible design results in a safe and efficient manner. This is where metal and steel laser cutting has stepped up in a big way which is highlighted by the fact that its demand in Melbourne and beyond has grown in recent years. Laser cutting machines have become prevalent in various industries, including pipe spool fabrication, due to its manifold advantages; this blog will look to discuss this in more detail.

Advantages of Laser Cutting

Laser Cutting

Laser cutting is a technology that uses a laser to cut materials, typically used for industrial manufacturing applications. It works by directing the output of a high-power laser at the material to be cut. As a result, the remaining material will either melt, burn, vaporize or blow away by a jet of gas, leaving a clean edge. Some advantages in this regard are as follows: –

  1. Increased Precision – Traditional methods can make it difficult to achieve clean, straight cuts on steel. However, with a laser cutter, one can easily perform precise cuts every single time. This means one can consistently produce higher-quality products and meet your customers’ expectations.
  2. Faster Production Times – Again, traditional metal cutting methods can take a long time to cut through thick pieces of steel. With a laser cutter, the process is much quicker, allowing one to get products out to customers faster and improve overall efficiency.
  3. Reduced Waste – It can be difficult to achieve precise cuts without leaving behind metal scraps. When one uses a laser cutter, the process is much cleaner and there is very little waste produced, saving money on overall production costs and improving the bottom line.
  4. Improved Safety – Another significant benefit of steel laser cutting is that it can help to reduce safety hazards in the workplace. By using traditional methods, there is always the potential for accidents, given the variety of moving parts. Still, with a laser cutter, the process is much more simplified and refined, creating a safer working environment and reducing the risk of injuries.
Industry Applications

Industry Applications

Metal and steel laser cutting and design can bring many benefits to many industries. This technology can help speed up production times, improve accuracy and precision and create more intricate designs. Some industries benefitting in this regard are mentioned as follows: –

  • Agricultural: Laser cutting can create highly precise parts for agricultural machinery, resulting in improved performance and longer life for each machine.
  • Contract Manufacturing and Fabrication: Many contract manufacturers currently use a metal laser cutting machine via steel fabrication to produce custom parts for their clients. This allows them to create complex shapes, designs and geometries that would otherwise be difficult or impossible to produce.
  • Military: The military also uses metal laser cutting machines to produce a variety of parts and components, including armor plates and small arms parts. The process allows better maintenance of the highest standards of quality and performance.
  • Construction: Many building organizations utilize laser steel cutting to create a variety of parts and equipment for construction projects, including everything from metal studs and beams to door and window frames.
Conclusion

Proper and precise cutting of metal and steel is intrinsic to the success of multiple projects. Laser-based cutting has a wide variety of applications and it is safer as well compared to other cutting techniques. As the fabrication world looks to streamline its operations, steel laser cutting is likely to play an important role going forward – hence, we can expect this technique to remain in the spotlight!

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