Metal Machinery

How to Effectively Remove Abrasives in Water Jet Machine Cleanout?

When abrasive water jet machine cutting technology was invented and fully developed, it provided a much-needed reprieve to the manufacturing and metal fabrication industries.

technologyThis success can be attributed to the numerous benefits of the system over existing cutting methods like punching, laser, and plasma cutting. It quickly rose in popularity due to its unparalleled performance, high level of precision, capacity, versatility, and productivity.

Much like any other cutting methods, waterjet systems require routine maintenance from time to time. This will help these machines at their top form, and their output at their best.

The extraction and eventual removal of spent abrasives from the tank are considered among the routine maintenance works for this type of material cutting equipment. 

The abrasive materials used by a waterjet tank will gradually and eventually fill up until such time that it reaches the table’s working surface and will render it no longer usable.

The moment that time comes, it will call for thorough waterjet cleaning to keep the system going well. It is maintenance work that must be carried out with regularity. 

This can be done by employing any of the following methods.

Defining What Water Jet Cutting is All About

Water jet machines use a mixture of high-pressure water driven through a minuscule orifice to create a high-velocity jet stream. This jet of pressurized water comes out of it at a remarkable speed that can reach over 2X the speed of sound! 

It will be so intense that it can cut and slice through solid objects. Or, as some have put it, it can grind its way through your materials, no matter what they are. It works even on tough objects like metals. 

To further intensify its cutting power, the jet stream can be combined with sharp and hard abrasive particles like garnet. Garnet is particularly good for this purpose. The abrasive mixture is then directed back into the waterjet stream via a focus tube. 

The resulting abrasive mixture is then directed into a jet stream via a nozzle called a “focus tube”. It is then directed to the workpiece, where it is shaped and carved using CNC axis control.

Depending on the pump horsepower, the pressure used, and the application it was on, these cutting machines use around 34 up to at least 2 pounds of abrasive material during the entire cutting course. 

After passing through the material, the abrasive would break down into manageable chunks and settle to the bottom of the work tank, with the inherent risk of building up over time. Eventually, it will need to be removed, either manually or with the use of another automated or semi-automated machine.

There are plenty of options to keep your waterjet running and working efficiently with minimal downtime for tank cleanout and abrasive removal. Here are some of the methods usually employed for this. 

Automatic Abrasive Removal Systems

Automated abrasive removal systems are touted as the latest and most effective way to clean abrasives in a waterjet machine. They are built directly into the system’s tank and thus would automatically keep it clean. It is a simple and fast method that can be programmed to keep the water jet equipment free of spent abrasives. 

Portable Abrasive Extractors

A portable waterjet cleanout device is another excellent option. They are qualified as industrial-grade wet vacuums and are designed to suction up spent abrasive that has settled at the bottom part of the tank. It comes with a long hose and nozzle for this purpose. 

cutting machine

These vacuums can cover a third of what can be done by automatic systems. Another vantage point it can offer is, manufacturing bodies can use it on several of their water jet cutting machines. 

Shoveling Out the Waterjet Tank

Shoveling is our last process on the list, which is a standard procedure for new users of waterjet systems. A method like this involves the removal of abrasives with a backhoe or a shovel. But it is necessary to lock the waterjet first, eliminate the slates and grates, and clear the tank of water for a full tank cleanout work. 

If you’re operating with a backhoe, be extremely careful not to damage the motion components of the machine. If you employ the use of a manual process, the workers will have no other way but to climb themselves into the tank and manually shovel out loads of accumulated abrasives. 

Generally, this is going to be a full-day project if completed manually and thus should not be underestimated in any way. 

Repurpose Used Abrasive

Remember, you can repurpose used abrasive garnet particles for other applications. They can be recycled in a sandblasting procedure or you can have them as a filler in concrete mixtures or as a hardener in cement blocks. 

When trying to shop for a water jet machine for your material cutting concerns, one of the many factors you need to consider is how you can clean out and dispose of used waterjet abrasives. If you come across such an item that offers the greatest convenience in this area, consider it a good deal for purchase. 

Machinery Maintenance: A Must Prevent Failure

Risk management goes to the heart of company success. It comes down to protect your backside and firms that do not do that would not last lengthy. Numerous firms are not paying adequate interest to the danger of equipment deterioration that eventually causes failure.

Think about these business dangers:

  • Equipment that should be prematurely changed due to too much wear and tear.
  • Productivity losses as well as operational hold-ups because of device failures.
  • Possibly massive expenses (consisting of obligation direct exposure) of on-the-job mishaps due to faulty devices.
  • Non-compliance with regulations and policies (e.g., safety and security, environmental) because of defective tools.

Stopping work to attend to these threats leaves your “backside” wide open.

engineering

Machinery Maintenance: What Should Be Done?

These are the business procedures businesses can carry out to lessen the threat of equipment failing.

1. Normal assessments

Whether it is a power saw or a multimillion-dollar crane, it is common sense that thoroughly inspecting devices before each use is the most effective method to ensure that they will not fail during the procedure.

With a user-friendly, equipment-specific assessment list system, you can guarantee that pre-use inspections are done effectively and recorded.

2. Reactive upkeep

When the equipment does stop working– or far better, when an examination recognizes trouble to be resolved before an in-use failing– responsive upkeep happens. This is “repair it” upkeep.

Nonetheless, you could decrease the risk of tool failure in your responsive maintenance procedures by insisting on appropriate solutions instead of enduring (or encouraging) a “get it back at work ASAP, despite just how” attitude. The palpable temporary pain of device downtime should not lead to a rash or insufficient repair service that reveals the firm to possibly much-costlier functional conformity, as well as responsibility danger.

3. Preventative upkeep

Businesses that adequately appreciate the adverse economic influence of equipment breakdown do not wait until tools fail to provide their focus. They have a defined maintenance procedure to remain on top of the routine treatment the tools require and replace parts corresponding to the schedule.

machine repair

They likewise train workers on how to utilize the equipment in as non-destructive means as possible– which practically might not be “maintenance” yet undoubtedly helps in reducing wear on tools. (Since it is humane to care much more about things you oversee, the method of having workers carry out regular pre-use examinations usually causes gentler treatment of tools– simply one instance of how these four procedures match each other.)

4. Anticipating maintenance

This is the procedure of using historical data and the ongoing dimension of equipment during the process (e.g., checking load-bearing ability) to anticipate when it will stop working (or drop below operational criteria) and take rehabilitative activity before then.

Anticipating maintenance is preventative upkeep taken to a lot more proactive degree. It suggests a firm that gets the relevance of keeping equipment in ideal functioning condition.

All-time Low Line

Business can considerably lower equipment failure by integrating normal, appropriately carried out equipment evaluations with a machinery maintenance plan that includes predictive upkeep and reactive maintenance.

Benefits of On Site Air Compressor Repairs and Preventive Maintenance

Regardless of your compressor operation’s dimension or extent, it is important to have someone on personnel or deal with a competent company, to supervise preventative upkeep work on a prompt and constant routine. Only with preventative upkeep can you guarantee the makers will function hour by hour, every day, and remain to operate to their complete life expectancy.

On Site Air Compressor Repairs Benefits

Staying clear of Downtime

Among the primary benefits of air compressor upkeep is that it makes the machine run better and much more effectively and reduces occurrences of a system interruption. As anybody who operates an air compressor facility understands, Downtime could be a pricey issue since when the equipment stops working to operate, it halts production.

A business that stops working to enact prompt maintenance procedures runs the danger of experiencing efficiency concerns with greater incidence. Such events are hard to anticipate yet can occur at the worst minutes, such as when high-cost manufacturing is underway with an established target date. To be on the safer side, you require to execute maintenance as planned without skipping a day, even on days when all seems to be running correctly without any possible troubles visible.

Saving Money by Staying Clear of Costly Emergency Repair Services

With reduced downtime incidents and component failure in the air compressor system, you can save money. Thus, you gain both ways– with increased Performance as well as decreased expenses. The cash you save with timely compressor upkeep permits you to spend extra on far better tools as advancements get to the marketplace.

Without upkeep, the costs involved in the repair service of an air compressor and its outer parts could take a massive portion from a company’s yearly profits. When you perform timely upkeep, you will reap savings you could hand down to your company through more excellent wages as well as less expensive products.

air compressor

Lower Energy Costs

When you execute on site air compressor repairs on a regular schedule, it enables you to capture circumstances where a function in the system is over-utilizing or having a hard time preserving an expected manufacturing price. When such concerns arise, it is frequently to a part that requires cleansing, replacement, or lubrication. By identifying these issues before they get out of hand, the device runs smoother and much more successfully, converting to power cost savings.

Power cost savings additionally amount to money collected in your general manufacturing prices. With reduced regular monthly power prices, you can spend the cash back right into the facilities of your business.

Rise Air Compressor Life as well as Performance

Naturally, the best value of air compressor upkeep is that it improves the life and effectiveness of the equipment itself as well as the system. When you build up the preliminary cost of investing in an air compressor and all the affixed pneumatic kits, you wish to guarantee a return on that asset through years of ideal efficiency. Preferably, the cash you spend on your system ought to compensate you thousands and hundreds of times over via efficiency.

Without upkeep, your air compressor and its outer parts will certainly not last if it or else can with regular examinations, tune-ups, and cleanings. When you evaluate the earnings of companies that execute accountable system maintenance, you are likely to see significant distinctions in inefficiency.

How to Keep Your Waterjet Machine Running Even During the COVID-19 Pandemic?

The moment you have seen how water jet machines work, you will understand the underlying reason why people working behind the metal fabrication and manufacturing spheres consider this method of cutting as a versatile alternative to laser, plasma, and mechanical slitting machines.

Quite the opposite of thermal cutting, they can process metal cutting procedures sans the creation of heat-affected zones or HAZ. This explains the reason why waterjet machines were elevated to becoming one of the most preferred materials cutting methods for processing of metal parts for use in the construction and aerospace applications where even slight alterations in the metallurgical properties could create a significant impact to the overall integrity of the material.

Over the years waterjet systems, together with many other material cutting methods, had to undergo some inevitable changes for improvement. Some of the inherent attributes of newer systems of these material cutting methods would be their ability to cut your material faster and in a  more precise manner. Accuracy is key. In addition to that, they are also far more reliable for a more elevated uptime.

Advances in engineering and system diagnostics that portend of a looming problem before it even starts have rendered water jet systems as the more dependable and reliable material cutting method as opposed to those that were designed about a couple of decades ago. By this measure, maintenance is somewhat more predictable, generally minimizing downtime.

In any waterjet system, probably what can be considered as the hardest working part would be no less than the intensifier. With all the moving parts and components that it has, the odds that something could go wrong about it is high. The most common issues about it include water leaks, short seal life, and overstroming.

Overstroking

There is nothing unusual to an intensifier that strokes faster while on startup mode as well as when it is trying to shift between high pressure and low pressure. But if it is under normal operation, it should stroke smoothly and seamlessly to the left and the right at just about the same speed.

There would be occasions though that the hydraulic piston would be traveling faster in just one or with both directions. Sometimes going even beyond what the pump can provide support in, this is referred to as overstroking.

Water Leaks

Water leakage is another area of great concern in water jet systems. One of the most complained about causes of water leaks in the intensifier has something to do with damage to the water seals and the hoops.

If there is a visible presence of water right after every few strokes, take this as a sign that the seals are closing in to the end of their shelf life and with that, you need to prepare for a replacement anytime soon.  Or that you can just opt to change the seals at the soonest opportunity.

Presence of leaks in other areas, it might be an indication of a worn-out part, damaged seat or loose-fitting. Addressing such leakage at the soonest is of paramount importance to prevent damage to spread in other nearby components.

Short Seal Life

If there are a handful of telltale signs that your high-pressure water seals are not entirely durable and may have a short shelf life,  there are several practices you can observe to somehow lengthen up the interval between maintenance works are:

  • Ensure that the quality of the water itself is within the range of satisfactory levels. 
  • See to it that these two are within the set minimum requirements, water pressure, and volume. 
  • Clean all parts and components when replacing seals, and in doing so ensure that they are free of any debris. 
  • Thoroughly inspect the high-pressure cylinder ends for any cracks.  
  • See to it also that your hydraulic cartridge or plunger bearing is not worn.

The simple and easy to follow troubleshooting steps given above can be observed even when we are in a community lockdown due to COVID-19 pandemic. Provided that you follow them to a T and you’d see yourself saving not just money but your valuable time, too, from a service technician. This way you can rake in more profit by keeping your water jet machine in good working condition.

The Importance of Machinery Maintenance in Manufacturing

In manufacturing, any unexpected failure could interrupt the schedule of production and even lead to expensive downtime. This seriously impacts the bottom line.

Regular maintenance is one of the best ways to prevent any catastrophic failures. It could pay off in the long run as it increases operational efficiency and lessens cost.

Machinery Maintenance in Manufacturing: Why is it A Must?

A well-functioning equipment is a worthy investment. Below are a few long-term benefits of performing a preventive maintenance on your equipment.machine maintenance

  • Prolong equipment lifespan and lessen the need to buy new equipment.
  • Avoid unplanned downtime which could be costly and disrupt the process of manufacturing.
  • Prevent the need for costly repairs due to neglect.
  • Keep the machine running without any interruption to make sure that projects are completed on time and within the budget.
  • Guarantee that the systems are functioning efficiently to decrease energy expenditure and operational costs.
  • Avoid minor issues from becoming big problems that could be time-consuming and expensive to fix as complex repair usually comes with a higher price tag and much longer downtime.
  • Boost the resale value of the machine with a good service record.
  • Enhance equity, as well as borrowing strength by upkeeping assets value.
  • Lessen injuries and deaths, and thus liability, due to defective equipment.
  • Extend warranty coverage with detailed service records to show that the maintenance is up to date.

Manufacturing Equipment Service: What is Involved?

The aim of machinery maintenance is usually to make certain that your gear is running at hundred percent efficiency almost as possible while upholding probably the highest production quality.

With the tool of the newest technologies, like the Internet, cloud computing, and smart sensors of things, manufacturing technology upkeep has long gone beyond routinely scheduled trips by technicians.

For instance, smart sensors can alert plant managers of possible problems in real time, so they are able to be remedied before the issue interrupts the generation process.

Additionally, a workflow that features weekly or daily inspections, lubricating, cleaning, and minor adjustments can stop major issues from building.

Ensure Proper Equipment Maintenance

By creating simple tasks into your operation methods, you can make certain that the gear is properly maintained:

  • Set up procedures to evaluate the performance data from your monitor and system their operation so you can come to be aware of possible problems before they come to be a problem.
  • Provide adequate instruction to operators and technicians so that when an issue is detected, they can identify the issues and know exactly how to deal with them appropriately. Additionally, the right training can prevent overuse or misuse of equipment to stay away from unnecessary repairs.
  • Assign duty and make specific staff responsible for the best functioning of the gear. Empower as well as educate the right personnel to make certain the success of preventive maintenance.
  • Implement a maintenance routine as well as conduct standard inspections to avoid wear-and-tear that will turn into bigger issues.

Establishing a good equipment maintenance workflow is important to assisting your manufacturing facility work at probably the highest efficiency and improving the bottom line of yours. This is not a thing to skimp on as well as the energy will pay off in the end.

Farm Machinery Repair and General Maintenance

Farming equipment is very important. But, they can vulnerable to breakdowns given the fundamental nature of the job of theirs. Taking a look at the expenses involved when buying and repairing this gear, sensible producers place great focus on care that is appropriate and upkeep of farm machines.

Though there are a variety of fundamental maintenance services which are actually readily available in handy for each farmer, care and maintenance of equipment and farm equipment differ grounded on one’s requirements.

Farm Machinery Repair as well as Maintenance Tips

Lubrication as well as cleaning Farming machinery as well as equipment are actually certain to become dirty every stage you use them. Nevertheless, it should not stop you from attempting to always keep them fresh. Cleaning is actually essential for preventing issues like rusting and clotting. Eliminating the grime along with mud moreover clears the means for uncomplicated inspection so you’re able to easily determine defects like oil leaking as well as splits, among others. Last but not least, cleansing also will go rather a distance in guaranteeing your farm machinery’s longevity.

Lubrication and Cleaning

Lubrication is as essential as cleaning with regards to farm machinery repair and upkeep. Each movable part of the farm machinery in addition to equipment needs to be lubricated to stay away from friction. This friction is actually among the main reasons for the use and tear of actual physical machinery. This leads to expensive breakdowns, and even contributes to bad performance, as well as shorter life expectancy for the machine. You will need to use high-quality lubricants.

Rusting 

farm machineryRust is likely the biggest concern for farm tools. Exposure to a garden soil eats away the metallic with a period, along with this covers the machinery’s effectiveness. Rusting in its engine along with other internal components could also compromise the machinery’s integrity and necessitate expensive repairs.

Good thing that it is possible to stay away from rusting, or perhaps possibly at least set it all. The very first solution is actually keeping your farming tools and machinery totally clean by making clean them after use; merchant them in a factory in that they’re competent to continue to be dry looking out from the strong environmental components, especially during the stormy season.

You’re able to similarly go the extra mile to stay away from rusting with your agriculture equipment along with resources by covering them in paint and wax – this will keep them looking amazing. You’re able to similarly spray them in the distinctive anti-rusting spray.

Have the Glasses Intact 

The cup on the tractor, as well as the car, is actually meant to keep you shielded as you go about the efforts. Unsurprisingly, your car glass is bound to create perhaps cracks or perhaps even shutter.

Most likely the smallest defect on your car glass should never be taken for granted. You are assured to search for automobile glass items for whichever matter you are dealing with. Just in case it is merely a little crack, then consider the machinery in for car glass repair. More serious defects, nevertheless, may necessitate a broad auto glass replacement.

Be sure you seek out the best automobile glass services. High-quality services would not just ensure the longevity of the machinery’s cup but furthermore, fortify security whenever you are out in the business.

Schedule A Professional Inspection

The easiest method to ensure which your farming machinery is actually in a shape that’s great is actually by consulting a certified mechanic. The auto mechanic will do a comprehensive assessment especially for the engines along with various other important components that may be beyond the grasp. The auto mechanic also can certainly do some necessary maintenance necessary to always keep the machinery in shape which is actually good. It is the same recommendable to take operator training programs especially in case you are working with innovative farming machinery.

Conclusion

Farming equipment is a crucial purchase you can’t afford to lose. Such should serve you for numerous years, as well as the absolute best way to make certain it continues to be in the device for so long as you actually can by taking necessary care of it. All these farm machinery repair tips might get you started as well as keep the farming machinery fairly effective and safe.

Do You Know What a Plasma Cutting Table Is?

When planning to embark on the use of CNC cutting technology for your material cutting projects, you must know some of the basics first. Like for instance, you need to familiarize yourself with what a plasma cutting table is, what it is used for, and its relevance to this kind of material cutting system, overall.

It is no ordinary table used for industrial cutting processes but it is a kind of robotic in the sense that it incorporates the use and the functionalities of a handheld plasma cutter. It has gained widespread use and acceptance in the metal fabrication industry because it is easy to maintain and comes packed with a variety of features.

The capability of your CNC cutting table will depend upon what brand it comes in. In the case of plasmacam tables, they usually come in 4ft by 4ft dimensions. For this type, you can make use of materials sheets that are 4×8 ft or 4×10 ft. Now as for the machine itself, it is capable of handling images to a maximum of 20 ft long.

Power Requirement for a Plasma Cutting Table

In order to operate a CNC cutting table, it would require that you supply it with 3 amp electrical power. The cutting table itself usually would weigh about 300 pounds. Approximately, dimensions would run from 64 inches wide and 60 inches deep, the height would be around 90 inches. For a Plasmacam, the surface of the table would be around 33 inches high.

When it comes to the accuracy level for this type of machine, it would normally be a notch higher, a scale above a plasma torch.

CNC Application Systems

Every single manufacturer of CNC plasma tables for cutting comes with its unique bundle of system applications. The computer software or the application program that will be integrated into your computing systems, together with all the applications that it comes with are specifically designed and crafted to work with the table as if they are one and single unit.

Working as one unit, these systems are bound to take your business operations to its next level of efficiency by virtue of unique capabilities that you can take good advantage of in designing one of a kind masterpieces. You can also use it to come up with specialty parts.

The cutting table for CNC plasmacam Australia systems come bundled with repetitive capabilities with high levels of precision for every single cut. You can save the program up for a specific material cutting project and then have it out at a future date for use, confident and assured that the outcome would be the same as what it produced the time before. Combining CNC technology and robotics to develop a system will result in an indomitable and marvelous outcome.

Small scale business organizations can now have their long-awaited fair chance of increasing their level of productivity while at the same time removing also the high volume of waste materials they produce and high production costs. Being able to optimize the use of raw materials by virtue of cutting all the elements you require from the same sheet can save a fabrication company a significant amount of money in the end.

This will help pull down your production costs while at the same time keeping your revenue up. This is the ideal way we do business, right? 
If you have further concerns with regard to plasmacam Australia, the best course of action we highly recommend that you take is to reach out to a reputable dealer near you. They are the best people to answer whatever questions you may have in mind about their product offerings.

Top 3 Common Misconceptions on CNC Plasma Kits in Australia

Best CNC Cutting Machine

Managers in charged with overseeing CNC plasma kits in Australia manufacturing firms usually started their careers in other areas first. Nothing wrong with that, but they have very limited exposure and experience in the manufacturing space.

Thus, we can’t expect them to always have a profound understanding of what is going on inside the shop. So, when hurdles and challenges come to materialize they either have a hard time finding ways to resolve the issue at hand or grope in the dark.

Let us delve into some of the frustration-causing miscues that can be seen in the vast majority of shop employees and management people.

Learn CNC Programming

Myth 1: Anybody can run a CNC cutting machine

While a significant number of CNC profile cutters we have today were engineered to allow even an average-skilled person with minimal exposure and training in the manufacturing space run and operate such pieces of machines seamlessly, such applications are infrequent.

Truth is, to become a highly qualified CNC operator, you need to know how to carry out many tasks that require skills and need you to have vast knowledge about them, too.  

Such operator task may include cycle monitoring, cycle activation, work piece measurement, statistical process control reporting, work piece loading and unloading, acceptability evaluation, sizing adjustments, and dull-tool replacements.

The higher your expectations are for an operator, the more they need to know. This explains the reason why it is imperative to give them upskill training programs. Find out here.

Myth 2: A project task that was previously run successfully will still run without any problem or friction in the future

If your setup personnel run into a sticky situation in the job, the manager is likely to say, “I thought we had successfully run this job before”.

The presumption here is that since it was witnessed before the job was successfully run in the past, it would flawlessly run successfully again.

However, it must be noted that the manner in which the job was carried out in the past and the way in which it is executed in the present could run the risk of creating a potential problem. It is important to eradicate variations to make it possible to run jobs consistently without having to run into problems.

Myth 3: G-Code Programming is obsolete

G-code programmer
G-Code Programming

Managers are under the impression that when it comes to CNC programming, it can only get done with the use of a company’s dedicated CAM system. It is somehow true. The majority of companies employing CNC technology are also using a CAM system. Or in the absence of which they utilize instead something similar to it in terms of function and usability. 

It is of paramount importance for managers to know that a CAM system’s output is G-code. This is the exact type of G-code which manual programmers write out. It is also the exact G-code program that a CNC machine is capable of executing. 

If in case one of your setup personnel ran across a G-code program that needs changes, it is more convenient to implement required tweaks at the machine level. It is much better that way as opposed to having a  programmer make the required G-code changes under the CAM system. Or restructure the entire G-code program and have the same sent back to the machine. 

When it comes to changing programs at the machine level, it comes to follow that you understand G-code programming to its core.

The Takeaway on CNC Plasma Kits Australia

To become a highly efficient CNC programmer, it is imperative to have an in-depth understanding and knowledge on machine operations, processing, cutting conditions and cutting tools. He also needs to have a good orientation on how setups are made.

It is also expected from a good CNC machine operator to know how to direct operators and setup people. They are the end-users of the program they create.