Benefits of 5-Axis Waterjet Cutting

Also Published In - MAN (Modern Applications News)

Problem

GNB Corporation has a proven track record of manufacturing high quality, reliable products since 1968. They are known primarily as a manufacturer of large vacuum valves; however the company offers a diverse range of products and services, such as machining, welding and assembly of custom metal tanks and fabricated structures. Additionally, they have standard product lines consisting of vacuum gate valves, angle & pendulum valves, vacuum chambers, and custom flanges and fittings.

Located in Elk Grove, California the 50,000-square-foot facility’s full complement of fabrication, welding, assembly, and test equipment assures the highest product quality and reliability.Near the end of 2007 they realized they faced a situation where weld preparation and set-up times were higher than actual welding times. They decided they would benefit by adding waterjet cutting capabilities to their fabrication services. They were primarily cutting 6' x 12' x 1/2 " thick stainless steel (up to 5 inches thick) and needed a method of cutting material with the beveled weld preps directly onto the net shapes of the parts. Their goal was to eliminate all machining, beveling and grinding during the weld preparation process.

Angle Valve Project

One of the unique manufacturing challenges was presented by GNB’s angle (or poppet) valve product line. The body of an angle valve is constructed of two cylindrical tubes that intersect one another at a right angle. In the past, GNB made this body by coping the tubes by hand using a printed paper template. This was an expensive and time consuming process.

GNB's goal was to manufacture the body of their Angle Valves by waterjet cutting the flat plate with all penetrations prior to rolling. Many said this could not be done, and it did prove to be initially difficult. Not only are there penetrations for ports, there is a large branch port which requires perfect match up (see figure A below). Rising to the challenge, and, after several attempts, GNB now accomplishes this task quickly and with exacting precision.

The knowledge garnered from the Angle Valve Project has spawned many other benefits that the 5-axis cutting head has provided. GNB has virtually eliminated the grinding of weld preparations. This experience now applies to all GNB’s products as they constantly look for ways to save time and provide the highest quality products to their customers.

Benefits

By now, just about everyone in manufacturing understands the benefits of waterjet cutting. By far the most important benefit of the waterjet cutter is the ability to cut material without interfering with the material’s inherent structure as there is no heat-affected zone. Minimizing the effects of heat allows metals to be cut without harming or changing intrinsic properties. In addition, waterjet cutting is considered a “green” technology. Waterjets produce no hazardous waste and the garnet abrasive is a non-toxic natural substance that can be recycled for repeated use. Waterjets also eliminate airborne dust particles and contaminates which greatly improves the work environment and reduces problems arising from operator exposure.

By investing in a WARDJet 5-axis waterjet, GNB has cut their production costs and has increased material utilization rates. When discussing the benefits of waterjet cutting Kirk Carter commented, “In this competitive business environment, GNB could not afford to be without its 5-axis waterjet. We are focused on providing the best value for our customers and the WARDJet machine gives us a competitive advantage.”