Waterjet Cutting Advance

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High cutting performance at low pressure with water abrasive suspension

With its innovative new abrasive mixing unit, waterjet cutting specialist ConSus ANT is enabling the stationary use of water abrasive suspension (WAS) systems in the processing industry. A continuous suspension jet provides a more efficient cutting performance at lower pressure compared with conventional water abrasive injection (WAIS) systems.
In many industries, materials research regularly develops new materials for which suitable machining processes must be found. For a large number of materials, waterjet cutting with WAS proves to be technically superior and economically more profitable than conventional cutting techniques. Compared with WAIS, the ConSus suspension jet operates at less than half the pressure and up to three times as fast. The user receives thin kerfs without hardening or material deformation. The company is demonstrating its strengths particularly at increased cutting depths.

Suspension process convinces with higher efficiency

In contrast to three-phase WAIS systems with water, abrasive and air, the ConSus WAS system operates with a two-phase cutting jet of water and abrasive having a precisely adjustable flow rate. ConSus applies high pressure to the suspension before it reaches the remotely handled cutting nozzle. The high level of energy creates a cutting jet that emerges at almost twice the speed of sound. Its efficiency is much higher than that of the injection process, where turbulent mixing losses occur due to the contained air. The more focused WAS jet cuts precisely through even the hardest materials. That way, material with a thickness up to 1,000mm can be cut, while still maintaining a very good surface structure.

Less energy consumption, wear and emissions

ConSus operates at a maximum pressure of 1,500 bar, even at enormous material thicknesses, which significantly reduces energy consumption and component wear. Due to a patented airlock process, the system also offers advantages in terms of work safety. Studies by the Fraunhofer Institute for Production Technology confirm that, even at maximum working pressure, noise levels are around 70% lower than an injection jet operating at 5,000 bar. Low system pressures and high abrasive loadings, which are characteristic of the new system, also reduce the emission of solid particles by up to 50%.

Quick comparison of WAIS and WAS

ConSus can be integrated into any existing waterjet cutting system, whereby only the pump and control system need to be adapted. With no air or heat influence, it can be operated both above and below water. Performance and costs of WAS with ConSus as well as WAIS can be conveniently compared using a free web application. All relevant data, such as the type and thickness of the material that needs to be processed, as well as the required cut quality and calculation basis, can be easily customised.

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