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Line 124: − − == Safety == − The water jet can be a very dangerous machine if not used properly so here are some important safety items to keep in mind. First, Jesus forgives, but 30,000 psi doesn't. So pay attention to these precautions and be safe while operating this machine. − # NEVER, EVER, EVER, EVER, EVER turn on the machine without first turning on the water! You could destroy the machine...and your reputation. − # If you see water squirting out the side of the machine while running a cut, don't touch it! It is the fountain of "Bye Bye Fingers." − # Wear rubber gloves while dealing with the water in the tank. The water in there is a nasty pool of bacteria and chemicals just waiting to crawl into your open wounds. − # If you have true "talent" and manage to run the water jet while your hand is underneath it, you have the opportunity of going to the ER and taking with you a medical card that tells the doctors how to treat you so you don't die. − + + + + + + + + + + + +
no edit summary
|Has make=OMAX
|Has make=OMAX
|Has model=ProtoMAX
|Has model=ProtoMAX
|Has serial number=8100202
|Has name={{PAGENAME}}
|Has name={{PAGENAME}}
|Is located in facility= Machine Shop
|Is located in facility= Machine Shop
|Is used in domain=
|Is used in domain=
|Has certification=https://georgefox.instructure.com/courses/1303
|Has function=
|Has function=
|Has icon=File:waterjet_cutter_icon.png
|Has icon=File:waterjet_cutter_icon.png
|Has description=Used for precision cutting of tough materials.
|Has description=Used for precision cutting of tough materials.
|Has QR code=
|Has QR code=
|Has ace=Donald Williams;dwilliams16@georgefox.edu
|Has ace=Needed;Needed
}}
}}
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__TOC__
__TOC__
==Safety First==
[[File:Safety First HD2.png|left|150px]]
The waterjet can be a very dangerous machine if not used properly so here are some important safety items to keep in mind. First, Jesus forgives, but 30,000 psi doesn't. So pay attention to these precautions and be safe while operating this machine.
* NEVER, EVER, EVER, EVER, EVER turn on the machine without first turning on the water! You could destroy the machine...and your reputation.
* If you see water squirting out the side of the machine while running a cut, don't touch it! It is the fountain of "Bye Bye Fingers."
* Wear rubber gloves while dealing with the water in the tank. The water in there is a nasty pool of bacteria and chemicals just waiting to crawl into your open wounds.
* If you have true "talent" and manage to run the water jet while your hand is underneath it, you have the opportunity of going to the ER and taking with you a medical card that tells the doctors how to treat you so you don't die.
==Description==
==Description==
The waterjet Cutter is a machine that uses highly pressurized water with a flow of an abrasive material to perform computer controlled cuts on a wide variety of materials, including 1" steel. This is helpful for creating parts with intricate designs for car engines, mounting brackets, and decorative plates. Another benefit of the water jet is that there is minimal temperature change during the process which makes it perfect for cutting temperature sensitive materials. Check out the video below to see the water jet in action.
The waterjet Cutter is a machine that uses highly pressurized water with a flow of an abrasive material to perform computer controlled cuts on a wide variety of materials, including 1" steel. This is helpful for creating parts with intricate designs for car engines, mounting brackets, and decorative plates. Another benefit of the waterjet is that there is minimal temperature change during the process which makes it perfect for cutting temperature sensitive materials. Check out the video below to see the waterjet in action.
{{#evu:https://www.youtube.com/watch?v=UE4Fz8v0Lms&feature=youtu.be}}
{{#evu:https://www.youtube.com/watch?v=UE4Fz8v0Lms&feature=youtu.be}}
====Terminology====
====Terminology====
* Tool path - The path that the water jet will follow when cutting out a part. This includes more than just the outline of the part because the water jet must pierce through the material before performing a cut.
* Tool path - The path that the waterjet will follow when cutting out a part. This includes more than just the outline of the part because the waterjet must pierce through the material before performing a cut.
* ProtoMAX LAYOUT- This is the software used to set up a tool path for the water jet and can be found on the laptop that is used with the waterjet.
* ProtoMAX LAYOUT- This is the software used to set up a tool path for the water jet and can be found on the laptop that is used with the waterjet.
* MAKE - This is the software that directly communicates with the waterjet to perform a cut from a tool path. It can also be found on the waterjet's laptop.
* MAKE - This is the software that directly communicates with the waterjet to perform a cut from a tool path. It can also be found on the waterjet's laptop.
==== User Manuals ====
==== User Manuals ====
[https://knowledgebase.omax.com/protomax/content/accessories-home.htm?tocpath=MANUALS%7CACCESSORY%20%20GUIDES%7C_____0 Complete list of ProtoMAX manuals]
[[Media:Waterjet Cutter ProtoMAX Manual.pdf|Waterjet Cutter User Manual]]
==Training==
==Training==
====Overview====
====Operation====
The waterjet cutter is an amazing tool that can be used on a wide variety of materials including 1" steel! However, it is limited to a 12" by 12" cut area with a 1" thickness being its maximum. Make sure the waterjet cutter is capable of handling your part and your material before going through all of the setup procedures. Like cutting many other two dimensional cutting tools, the cutting process should begin with a DXF file created from Solidworks or a similar software. Once a DXF fie has been created it can then be used to create a tool path using ProtoMAX LAYOUT. The detailed steps to do do this can be found in the general procedure but the most important step is to ensure that the water jet pierces the material outside of the part outline. After the tool path is created and the machine has been properly set up, the job can be posted to the MAKE software, which is installed on the water jet's laptop computer, to perform the cut.
The waterjet cutter is an amazing tool that can be used on a wide variety of materials including 1" steel! However, it is limited to a 12" by 12" cut area with a 1" thickness being its maximum. Make sure the waterjet cutter is capable of handling your part and your material before going through all of the setup procedures. Like cutting many other two dimensional cutting tools, the cutting process should begin with a DXF file created from Solidworks or a similar software. Once a DXF fie has been created it can then be used to create a tool path using ProtoMAX LAYOUT. The detailed steps to do do this can be found in the general procedure but the most important step is to ensure that the waterjet pierces the material outside of the part outline. After the tool path is created and the machine has been properly set up, the job can be posted to the MAKE software, which is installed on the waterjet's laptop computer, to perform the cut.
====Demonstration====
====Demonstration====
'''Part Design in ProtoMAX LAYOUT:'''
'''Part Design in ProtoMAX LAYOUT:'''
# Open ProtoMAX LAYOUT. Your screen should look something like this. [[File:ProtoMAX_LAYOUT.png|none|thumb|600x600px]]
# Open ProtoMAX LAYOUT. Your screen should look something like this. [[File:ProtoMAX_LAYOUT.png|none|thumb|600x600px]]
# Select the "Line" tool from the "Draw" menu on the left of the screen and create a 2" square with a 1" square notch in the top right corner. To do this, click anywhere on the screen to start the first line. This will bring a popup "Specify Dimensions" box where you will enter 2 into the "Rise (dy)" box. This will create a 2" vertical line. Select the "Line" tool again at the top of the first line and enter 1 into the "Run (dx)" box. This will create a 1" horizontal line to the right. Repeat this process until the box looks like this. The last line at the bottom can by created by selecting both open edges with the "Line" tool. [[File:Basic_shape_of_box.png|none|thumb|600x600px]]
# Select the "Line" tool from the "Draw" menu on the left of the screen and create a 2" square with a 1" square notch in the top right corner. To do this, click anywhere on the screen to start the first line. This will bring a popup "Specify Dimensions" box where you will enter 2 into the "Rise (dy)" box. This will create a 2" vertical line. Select the "Line" tool again at the top of the first line and enter 1 into the "Run (dx)" box. This will create a 1" horizontal line to the right. Repeat this process until the box looks like this. The last line at the bottom can by created by selecting both open edges with the "Line" tool. [[File:Basic_shape_of_box.png|none|thumb|600x600px]]
# Select the "Circle" tool and choose the intersect option from the bottom of the screen. Click the top, left corner of the square and enter 0.5 for the diameter of the circle.
# Select the "Circle" tool and choose the intersect option from the bottom of the screen. Click the top, left corner of the square and enter 0.5 for the diameter of the circle.
# Select the circle using the "Select" tool from the "Edit" menu on the left of the screen (make sure to select the top and bottom of the circle). Next, select the "Move" tool from the left side of the screen and choose the "Intersect" option from the bottom of the screen.
# Select the circle using the "Select" tool from the "Edit" menu on the left of the screen (make sure to select the top and bottom of the circle). Next, select the "Move" tool from the left side of the screen and choose the "Intersect" option from the bottom of the screen.
Most of the time, you will not be using ProtoMAX LAYOUT to design a part. Thankfully, this program can accept ".dxf" files, but you still have to create the tool paths. If using a ".dxf" file, import the file to skip the last section and start here to give it a tool path.
Most of the time, you will not be using ProtoMAX LAYOUT to design a part. Thankfully, this program can accept ".dxf" files, but you still have to create the tool paths. If using a ".dxf" file, import the file to skip the last section and start here to give it a tool path.
Before showing you how to create a tool path, there are a couple of things that you must keep in mind. When the water jet cuts it has a kerf which means it will take away some of the material it is cutting and you do not want it to be taking material away from your part. Instead, you want to remove material from the scrap that is not critical to the part's function and as a result the tool path must be created with this in mind. To do this, you must first keep in mind that the waterjet will always cut on the left side of the tool path lines. This changes based on the direction the nozzle is traveling; for example if the nozzle travels clockwise around a circle it will remove excess material outside of the circle and if it travels counterclockwise it will remove excess material from the inside of the circle. Because of this, you must control the direction that the nozzle will travel. For an outside cut, you want it to cut on the outside of the line to preserve the proper dimensions of the part. For and inside cut, you want the opposite of that. For a ring, you would want the nozzle to travel clockwise for the outside cut and counter-clockwise for the inside cut. To control the direction of the nozzle, place lead-in and lead-out lines to specify the start or end of a cut and the cut direction. It is better to cut the inner bits first and then the outer bits last; and don't let the nozzle travel over any holes that are already cut.
Before showing you how to create a tool path, there are a couple of things that you must keep in mind. When the waterjet cuts it has a kerf which means it will take away some of the material it is cutting and you do not want it to be taking material away from your part. Instead, you want to remove material from the scrap that is not critical to the part's function and as a result the tool path must be created with this in mind. To do this, you must first keep in mind that the waterjet will always cut on the left side of the tool path lines. This changes based on the direction the nozzle is traveling; for example if the nozzle travels clockwise around a circle it will remove excess material outside of the circle and if it travels counterclockwise it will remove excess material from the inside of the circle. Because of this, you must control the direction that the nozzle will travel. For an outside cut, you want it to cut on the outside of the line to preserve the proper dimensions of the part. For and inside cut, you want the opposite of that. For a ring, you would want the nozzle to travel clockwise for the outside cut and counter-clockwise for the inside cut. To control the direction of the nozzle, place lead-in and lead-out lines to specify the start or end of a cut and the cut direction. It is better to cut the inner bits first and then the outer bits last; and don't let the nozzle travel over any holes that are already cut.
# Zoom in closer to the circle. Select the "Lead i/o" tool from the "Draw" menu on the left of the screen. Select the bottom edge of the circle and move the cursor upwards and click to create a lead in and out from the center of the circle. This will tell the water jet to cut on the inside of the circle. Looking at this picture, you can see that one line is longer than the other. This longer line is the lead-in line. The nozzle will penetrate the material from the beginning of the long line and work its way down to the bottom of the circle. Once the nozzle hits the bottom, it will start counter-clockwise because the lead-in line is positioned at a slight angle to make counter-clockwise and easier direction than clockwise. This is how you tell the nozzle which direction to cut.[[File:Lead_i-o.png|none|thumb|600x600px]]
# Zoom in closer to the circle. Select the "Lead i/o" tool from the "Draw" menu on the left of the screen. Select the bottom edge of the circle and move the cursor upwards and click to create a lead in and out from the center of the circle. This will tell the waterjet to cut on the inside of the circle. Looking at this picture, you can see that one line is longer than the other. This longer line is the lead-in line. The nozzle will penetrate the material from the beginning of the long line and work its way down to the bottom of the circle. Once the nozzle hits the bottom, it will start counter-clockwise because the lead-in line is positioned at a slight angle to make counter-clockwise and easier direction than clockwise. This is how you tell the nozzle which direction to cut.[[File:Lead_i-o.png|none|thumb|600x600px]]
# Next, place a "Lead i/o" near the bottom of the left wall on the square moving your cursor to the left and clicking to tell the machine to cut on the outside of the box.[[File:Lead_io2.png|none|thumb|600x600px]]
# Next, place a "Lead i/o" near the bottom of the left wall on the square moving your cursor to the left and clicking to tell the machine to cut on the outside of the box.[[File:Lead_io2.png|none|thumb|600x600px]]
# Select the "Line" tool and connect the long, lead-in line of the box to the short, lead-out line of the circle. This is a traverse line telling the machine to move from the circle to the box after it has finished cutting the circle.
# Select the "Line" tool and connect the long, lead-in line of the box to the short, lead-out line of the circle. This is a traverse line telling the machine to move from the circle to the box after it has finished cutting the circle.
# Use the line tool and click on the long, lead-in line for the circle. Place the other end of the line so that it is at least 1/8" past both the left and bottom edge of the part. This will be the origin for the part and the cut. It should look something like this:[[File:Design_with_traverse_lines.png|none|thumb|600x600px]]
# Use the line tool and click on the long, lead-in line for the circle. Place the other end of the line so that it is at least 1/8" past both the left and bottom edge of the part. This will be the origin for the part and the cut. It should look something like this:[[File:Design_with_traverse_lines.png|none|thumb|600x600px]]
# Now you get to decide the quality of each cut. Select the button at the bottom of your screen labeled "Quality". You should see a range from 1 to 5, a Traverse, and Lead i/o. The range of 1 to 5 will change the machines cutting speed. The higher quality is 5 (slower) and the lowest quality is 1 (faster). Choose a quality of 5 for the circle by clicking "5" and then selecting every part of the circle. Do the same for the outer edge but with a quality of 1. Your part should look like this. Leave the traverse lines as green. This indicates where you don't want the machine to cut. [[File:Quality_lines.png|none|thumb|600x600px]]
# Now you get to decide the quality of each cut. Select the button at the bottom of your screen labeled "Quality". You should see a range from 1 to 5, a Traverse, and Lead i/o. The range of 1 to 5 will change the machines cutting speed. The higher quality is 5 (slower) and the lowest quality is 1 (faster). Choose a quality of 5 for the circle by clicking "5" and then selecting every part of the circle. Do the same for the outer edge but with a quality of 1. Your part should look like this. Leave the traverse lines as green. This indicates where you don't want the machine to cut. [[File:Quality_lines.png|none|thumb|600x600px]]
# Sometimes there are extra points or lines that are unnecessary. To remove these points, click "Clean", click "start" on the popup window, and "okay" on the second popup window. Doing this will insure a tidier cut
# Sometimes there are extra points or lines that are unnecessary. To remove these points, click "Clean", click "start" on the popup window, and "okay" on the second popup window. Doing this will insure a tidier cut.
# The last step is saving the file to be cut. Click "Post" on the right of your screen. If you have not saved yet, this will ask you to save your drawing; do so. It will then bring you to a window asking you to "Pick Start". Select end of the traverse line that you defined as the origin.
# The last step is saving the file to be cut. Click "Post" on the right of your screen. If you have not saved yet, this will ask you to save your drawing; do so. It will then bring you to a window asking you to "Pick Start". Select end of the traverse line that you defined as the origin.
# A window will popup showing the tool path. Zoom in closer to your part and inspect where the tool path is. The program will display cuts as a thick red line. Make sure that these projected cut lines are on the proper side of the line that you specified. If all looks well, hit "save" on the bottom, left of your screen.
# A window will popup showing the tool path. Zoom in closer to your part and inspect where the tool path is. The program will display cuts as a thick red line. Make sure that these projected cut lines are on the proper side of the line that you specified. If all looks well, hit "save" on the bottom, left of your screen.
'''Waterjet Operation :'''
'''Waterjet Operation :'''
# Open the water valve located on the wall behind the waterjet. It will be open when the handle is parallel to the water pipe.
# Open the water valve located on the wall behind the waterjet. It will be open when the handle is parallel to the water pipe. Be sure to only turn in on BEFORE powering the machine.
# Check the pressure gauge to verify that the water pressure is 40 psi or greater.
# Check the pressure gauge to verify that the water pressure is 40 psi or greater.
# Fill the tank to the top of the metal ribs with the water hose on the right side of the machine.
# Fill the tank to the top of the metal ribs with the water hose on the right side of the machine.
# Check the garnet hopper. If it is low, fill it up.
# Check the garnet hopper. If it is low, fill it up.
# Power on the computer and plug in the USB.
# Power on the computer and plug in the USB.
# Power on the water jet cutter.
# Power on the waterjet cutter.
# Open MAKE.
# Open MAKE.
# Zero the water jet cutter head using MAKE.
# Zero the waterjet cutter head using MAKE.
# Push the clear plastic hose into the hole located on the side of the nozzle. This hose is called the abrasive feed tube and is used to mix abrasive into the water.
# Push the clear plastic hose into the hole located on the side of the nozzle. This hose is called the abrasive feed tube and is used to mix abrasive into the water.
# Position the nozzle between two of the metal ribs, close the lid, and test the nozzle using MAKE. When closing the lid, the support bar on the right side of the lid must be lifted otherwise it will not close. There are two things that should be checked when performing the nozzle test. First, check that the water is flowing through the nozzle. This is necessary because the nozzle can get clogged. Second, check that there is abrasive flowing through plastic tube. It flows quickly but can be identified by a sparkling in the tube as it flows.
# Position the nozzle between two of the metal ribs, close the lid, and test the nozzle using MAKE. When closing the lid, the support bar on the right side of the lid must be lifted otherwise it will not close. There are two things that should be checked when performing the nozzle test. First, check that the water is flowing through the nozzle. This is necessary because the nozzle can get clogged. Second, check that there is abrasive flowing through plastic tube. It flows quickly but can be identified by a sparkling in the tube as it flows.
# Remove the material and clamps from the work area.
# Remove the material and clamps from the work area.
# Remove the abrasive feed tube from the nozzle.
# Remove the abrasive feed tube from the nozzle.
# Position the nozzle between two of the metal ribs and run a nozzle test to clear any remaining abrasive from the nozzle and prevent future clogging
# Position the nozzle between two of the metal ribs and run a nozzle test to clear any remaining abrasive from the nozzle and prevent future clogging. Also known as purging the nozzle of garnet.
# Bring the nozzle back to its home position.
# Bring the nozzle back to its home position.
# Close MAKE.
# Close MAKE.
# Close the lid.
# Close the lid.
# Close the water valve so that the handle is perpendicular to the pipe.
# Close the water valve so that the handle is perpendicular to the pipe.
==Certification==
==Certification==
[https://foxtale.georgefox.edu/moodle/enrol/index.php?id=31413 Water Jet FoxTALE Course]
[https://georgefox.instructure.com/courses/1303 Canvas Course]
==Troubleshooting==
==Troubleshooting==
====ProtoMAX Layout====
[[File:WaterJet_Error_Message.png|150px]]
There are three different types of errors that can show up after you post
*Collision error
*Possible offsets to wrong side
*Inside radii is smaller than offset
If your program has a collision error, the paths are probably overlapping. try situating the i/o lines so that they do not overlap.
If your program has a possible offsets to wrong side error, it means it is cutting on the wrong side. One way to fix that is to change the lead in angle so that it leads into the direction you want to cut in.
====Water Jet Cutter====
There are a few common issues you may run into when using the waterjet. First, there may be an issue reaching the proper water level for your material. This is caused by the drain tube on the right side of the tank being at the incorrect height and can be fixed by pushing the drain tube up or down to remove water or allow more to enter. Make sure to wear gloves when doing this to protect from bacteria and never pull on the tube because it can be pulled off. If the tube does pull off don't panic; wait for the water to drain low enough to push the tube back on and then do so.
There are a few common issues you may run into when using the waterjet. First, there may be an issue reaching the proper water level for your material. This is caused by the drain tube on the right side of the tank being at the incorrect height and can be fixed by pushing the drain tube up or down to remove water or allow more to enter. Make sure to wear gloves when doing this to protect from bacteria and never pull on the tube because it can be pulled off. If the tube does pull off don't panic; wait for the water to drain low enough to push the tube back on and then do so.