Gas-powered waterjet cutter (follow-up) and other project updates
Вставка
- Опубліковано 29 сер 2024
- Build a capable waterjet cutter from a commercial pressure washer.
Sources:
Cutting head - www.accustream...
Orifice - www.accustream...
Mixing tube (nozzle) - www.accustream...
Pressure washer - www.amazon.com...
Pressure washer hose coupling (for brazing into cutting head) - www.amazon.com...
eBay CNC milling (eg) - www.ebay.com/i...
Applied Science on Patreon - / appliedscience
UPDATE:1 year and still cranks within the first 2-3 pulls. Probably will buy another when this one finally does bite the dust ua-cam.com/users/postUgkx43QMbQqu67IZadu9ou8Sg1BdrunMRNqX . No issues at all. Very happy with it.UPDATE: After 6 months of use and over 70 uses I would still highly recommend this pressure washer. It does vibrate a decent amount but never had it “walk” like others have mentioned. No oil leaks, still seems to run like the day I bought it. Still cranks within 2-3 pulls every time. Very happy with my purchase!Have used it about a dozen times now. Plenty of power, cranks up on 1-2 pulls every time. My only complaint would be I wish it was a little taller to make it easier to walk with it (hits my ankles a lot) and that the two hose connections were a little further apart but it hasn’t caused me any issues. Seems to run a good 1-1/2-2 hrs on a full tank, overall a well built machine and definitely worth the money in my opinion.
The garnet is reusable. 20+ years ago we dried and reused our garnet multiple times to increase cost efficiency. Very few of the particles actually do the cutting per cycle so 20-30 uses was typical for ferrous metals as we could use magnets to remove the metal particles from the slurry. We didn't concern ourselves with particles from materials that didn't rust/corrode in water or water/coolant mix and got up to 50 uses. Other abrasives that don't eat the focus nozzle are another area to increase efficiency.
Tape your glass a few layers and cut through this. It helps keep the glass mostly clear.
A tip for those who want to prevent the jet from penetrating the container and whatever is under it: Put in a lot of ball bearing balls. The will absorb the energy by the balls starting to rotate! This is used on commersal units meant to be put on top of the table on normal CNC machines.
I would be very interested to see you show the difference between fresh and used garnet using a scanning electronic microscope.
+1. Would also be nice to see some other abrasives, like grinding wheels and sandpaper, before and after being used.
This is exactly what I was thinking. On a 60ksi machine, the garnet isn't reusable, as most of the particles have broken apart on impact. But at only 3ksi, would the garnet be reusable, at least a few times?
you raise a good point, albeit actually recycling the garnet may be more hassle than it's worth.
It is literally wet sand. Yes, there's a bit of whatever you cut in there too, but that'll be even finer powder. Use fresh garnet for stuff that you want to ensure has no edge contamination, or that can be seen, and use the recycled stuff for cutting stuff that isn't cosmetic. A tiny amount of acrylic in your other acrylic? No matter. Some recycled garnet with mild steel in it on your fancy stainless steel? Nope.
@@DSSlocksmiths Good point, at least get 50% recycled and 50% fresh abrasive, and see how that works out.
Nice to see a non-clapped-out Bridgeport milling machine!
Cant wait for the mazak!
Mathieu MacAdam it’s probably going to be the messed up mazak ;).
Adam Savage has a really nice one, among a few other things
i suppose you know about ye ole uncle bumblefuck
Hi, nice video.
I used to work for a company where I operated a waterjet, in order to destroy the force of the jet the water needed to be about 1m deep, but interesting fact, if there's too much sand in the bucket the jet stream creates a eddy which excludes the water and you end up with a air column where the jet still cuts through the bottom of the bin.
I love that your "cnc control" is just clamping the water jet to your mill. Macgyver would be proud.
You have an excellent speaking voice and style. It is a pleasure to listen to you explain things.
Just found your project now. As far as the diameter ratio for the oriface and focusing tube, the 3x diameter principle is a rule of thumb but what really matters is the area ratio, which increases by the square of the radius as you go larger. With your (larger than typical) dimensions, I'd imagine you are well within or overshooting the traditional "rule of thumb." Food for thought, but nothing is better than practical experience! Subbed, Cheers.
To prevent your catch tank being punched through, use a deeper tank and fill it half way with foam, scrap metal, and water to dissipate the jet. The industrial ones have a 3-4 foot deep catch tank filled with water and steel shot. The shot has to be re-leveled every so often to prevent the jet from pushing it out of the way and punching through the tank bottom.
Not true. I run a 5-axis Maxiem 2030 at a job shop and 3-4 feet is bang on regarding the depth but all thats needed to dissipate the energy is to submerge the cutting head in the water. (Ours has a steel tank at the end thats open at the bottom and you pump air into it to raise the water level)
When the stream draws air with it down into the catcher tank (when its raised more than 50mm above the water line) it enables it to puncture deeper and all the way through the bottom of the tank.
Ours is a 50ksi machine but you would never need steel shot or foam or scrap metal for that matter. Although I sometimes cut really thick material (Mostly Acetal plastic to save on machining time but we sometimes do mild steel up to 110mm) where it goes super slow it still hasn't been a problem because the catcher tank also quickly fills with garnet and slugs and most of that gets IMMEDIATLY pushed far away from the main cutting area.
Variable solids removal systems are also optional on the Omax and Maxiem machines and they pump debris and garnet from the bottom of the tank into a hopper. Saves massively on downtime.
I'd be interested to see an application where the steel shot is used though do you have a source?
cheers Diddi Mar
My source was a OMAX rep about 6 years ago. I was doing purchase research for the company I worked for. Saw all the brochures, toured shops with machines, made up an operating budget, etc. They were the ones who recommended the steel shot in the tank bottom. Solids removal systems were available at the time. They were able to remove the garnet, but I think a waster sheet was recommended to protect the tank bottom instead of the shot in that case. The foam and scrap metal was only for the home gamer who might not have a 3 or 4 foot deep catch tank. That would cause all sorts of headache for an industrial machine.
what we can do for low pressure like 200-300 bars?
This will be the Best tiles cutting machine on earth Brilliant made thanks
The coolest "life-hack" i've ever seen.
Three videos in a span of two months, you're really spoiling us here.
The price doesn't really come into factor if you've hooked up to your neighbor's electricity and water supply.............
Now the problem is to get them to pay for a CNC machine.
Tree hahaha 😀
I'm sure you can steal a CNC machine if you're in to that sort of a thing 😀
I suspect performance would be greatly improved with an accumulator. Just like in the 25k psi machines. This model would be use a much weaker spring inside the chamber of course. This acts as a buffer between the pump and the nozzle, greatly smoothing pulsation and fluctuation in pressures, not to mention helping with the bypass valve issue.
You do some of the very best science experiments on YT. I look forward to many more!
I love these diy water jets you are experimenting with. Ive been messing around with something kind of similar to this with a cnc pressure washer for very very rough timber milling and joinery. (No aggregate) I kind of gave up on it a while ago, but this makes me want to get into it again. Your vids motivate me
I'm working on a project similar, but it's to use a more portable (by comparison to a standard cutter)
Aggregate and water mix to potentially cut rough stone.
Any advice from your own project?
If you use a cheap gantry CNC router as the basis for a waterjet, simply turn the entire machine upside down, so the bed is above the gantry, then build a tank and cutting rack below all of that.
AP this is what you meant by an eBay cnc?
comparing the two units.
with A having a flow of 1.7 vs 2.8 gpm of B (Petrol motor) the flow is 64.7% more in B.
the area of the nozzle for B is 26.6% more than A based on the nozzles of 0.040 vs 0.045 diameters
therefore the flow velocities through the two nozzles is 30.14% higher in B
therefore the increased energy in B due the square of the velocity is 69% more. which is not insignificant.
thanks for the update,
Charles The metal bucket certainly noticed the increase in energy!
Applied Science I'd say your concrete floor was more impressive. Glad you didn't find a sewer line there.
/r/theydidthemath
Fun fact, I downloaded the WardJet feed rate calculator, and your numbers match very nicely to what the calculator spit out. Even tho the calculator said anything below 20K PSI is "out of range" LOL
so I think I may move forward and try to make my own soon. Thank for the info!!!!!
how have you managed to learn so many things on so many fields of study? You know so much stuff it's almost unbelievable
Because he is interested in many things, likes learning new things, and probably has a great memory. He probably also detests paying other people to do things for him, or at the least, feels much more satisfaction when he learns to do the job himself. Whereas most people would just pay someone to fix their Computer, he would probably rather learn the skills to do it himself. And he won’t forget those skills due to the excellent memory.
My wife asks me that question often. Then, when I’m on the computer at 2am reading stuff, or in the garage until 2am playing with stuff, she wonders what I’m doing. I tell her, “I’m learning all that stuff I know”.
I am working on building a general body of knowledge to try some projects like this, but I have years and probably even decades before I can get close to anything as varied as this. (I am currently working on a more specialized education as well which can help)
Just a thouht. The electric pressure cleaner you used had an universal motor for power source, which does have a very limited duty cycle and short but merry life. if you can get a used industrial pressure washer ( generally WAP) that has an induction motor as drive, these are rated for continuous duty, perfect for this application. Also they have better pump liners and you just need to replace the pump oil with new high EP agent oil to get it to run nicely. Also generally available used, and looking like they were dragged through a mine by the hose, but so long as the pump itself and the motor are fine well worth it, and the pump assemblies can be rebuilt with a kit as well.
I click so fast when I see a new AP video, they're so good!
JZL003 Agreed! Instant watch. Easily the youtube channel I'm most excited for uploads.
A very common application for these is in a automotive paint shop where they are used for blasting off the accumulated layers of paint on the carriers. No abrasives were necessary, but then again each pump is powered off of up to a 500hp motor. The nozzle rotates, and has a cutting "surface" of about 3 inches in diameter (we just want the paint off, we don't want to actually cut the carriers in two).
The cleaning head is attached to a robot, which runs its path to clean the carrier. The head of the cleaner is nearly bulletproof, and the carrier is essentially a large hunk of steel. No better place to learn robot pathing than in the cleaning booth. Even if you whack the carrier with the spray head, no harm done. You're there to take the paint off of the carrier one way or the other... :)
And since each carrier is cleaned after 50 - 100 trips through the paint booth, the paint buildup will be made up of many layers of different colors (think red car, green car, blue car...). So the larger pieces of paint blasted off of the carriers were often collected by the guys in the paint shop, and then sanded down and polished to show the various layers in the chip.
*The only channel that shows and tells you the results in the first minute* even our loved tech ingredients is all disgusting clickbait titles and thumbnails and cliffhangers now, and our favorite practical engineering does the same slimed cliffhanger clickbait stuff. Sorry NileRed, and medhi. Truly a one of a kind channel.well AvE too lmao
Can't wait to see what 2018 has in store!
Wait until we get to 2019... it's gonna be a hoot.
If only I weren't doing another really expensive and time-consuming project right now. This is amazing!
I thought "homebrew waterjet cutter it's really big deal?" until I looked for factory made cutter...
Damn its cost like a car! Great job, it's so impressive!
I can’t get enough of your videos. I need to buy a house so I can have a shop and do fun stuff like this.
To protect the glass from sandblasting, place it on a sheet of mdf like 1/8", and cover both sides of the glass with plastic tape thicker the better. Good job btw.
Ben''s christmas Jules Verne adventure. always a pleasure to watch. Im building a glass oven next week.
Nice new intro :)
Ha ha ha - what a HOOT! Imagine what a delightful COMFORT it was to sit down to this video just when I did! The washing machine started acting up, seeming to have trouble filling with hot water but warm or cold seemed OK - so I pulled the hot side supply line out and found, as expected, chunks of rust plugging the screen! It's NICE when it's EASY - or so I made the mistake of THINKING!!! Twisted it to final rinse/spin to see if it would work, and it seemed to be - so I went on to something else. Suddenly - the HUGE WHOOOOOSH - as the (front loading) washer popped the door open because it filled WAY TOO HIGH and failed to DRAIN at the very end of the cycle. Water pouring out all over the wood floors, in hallway, adjacent bathroom and the bedrooms - sending me SCRAMBLING for my shop vac and all the towels I could find. WOW! So after I get it all cleaned up and crank the heat up and turn on several fans I sit my tired, drenched booty down and fire up EweToob to recoop a bit. Might as well check YOUR channel, one of my favorite cognitive stimulators, and --- WHAT???? Here's YOUR tale of a similar blow-up of a domestic flood - however did you know there's be some miserable one in need of company like this? Thanks LOADS!!!! I really needed to laugh about it! (before I go try to finger out what happened!)
Keep up the excellent work!
New intro is great. Short, Appropriate, Fits well with your channel.
So cutting a 2mm steel sheet is possible... Wow man. Thank you so much for the video! Great job!
You just built a waterjet that cuts steel for less than 1000. WOW
This waterjet is awesome. One possible improvement. If you can adjust the unloader pressure to where it works as designed you can get an electrically operated high 3,000 psi water valve from McMaster-Carr for $170. That gives you the ability to turn the "cutter" on and off electrically.
How do commercial waterjet cutters deal with the problem of cutting through the bottom of the bucket?
Thanks for the tip about high pressure valves at McMaster. I never knew they had super high pressure valves. It looks like they have some 5000 psi valves for $110 ! www.mcmaster.com/#1190n22/=1avxi42 It would be interesting to do some flow rate tests on these. Someone in the comments said that commercial machines have steel ball bearings in the bottom of the tank to dissipate the energy of the jet. Seems like a good idea.
@@AppliedScience You could use the commercially available pneumatic valve body like the big boys use. I have seen some on ebay, rated at 60K PSI. Aliexpress sells a "entry level" complete head unit: nozzle, mixer, orifice, mount and valve for about $300USD
Hilarious is I find these pressure washer engine very often for free to $50 for the horizontal shaft engines. I've actually invested in three of the GCH's and GCV's, though for air compressor system testing and washing for now. Maybe eventually for water jet cutting since is on the mind. Amazing... then another not even $100 for a new pressure washer pump where most the washers have the rest of the parts other than required for cutting. Thanks for sharing! For some reason I missed this video.
As of late, wondering about converting an air compressor to run off the GCH gas engine with a solenoid to control the throttle with the go cart clutch. Thinking I can remove the flywheel and epoxy some neodymium magnets and install a GX stator. Otherwise... maybe lap a GX flywheel to fit the GCH... then it's like scope creep to just invest in the electric starter kit that has all the parts. Unfortunately, I don't see much, if any of the electric start GC's though I guess they exist. Doubt for under $50 though.
What's the thickest aluminum and steel material you can cut?
So awesome!
hey bud, I miss you
Samy Kamkar is a legend in his own right
What in the world, I missed both the original project video and this follow up.
Once again; your most interesting (for myself at least) project yet. Genuine _applied science_ at it's best.
Thank you for internationalizing your content by adding the metric equivalent values in the brackets
id be so happy if that ruby laser got put onto a frame with a handle and trigger, even if its got a whole cabinet of capacitors and tubes stuck to it it'd look badass
routing the hydraulic pipe may be the biggest challenge. a small cnc may struggle with the forces. If you are prepared to dry and reuse garnet then just find a proper wj shop they will be happy to let you have some (we get through tonnes of the stuff )
Dude, dude, dude... this is bloody sweet!
Neat little intro and nice to see a follow-up of this project.
another way to save on the pressure washer would be get a 212cc Predator engine from Harbor Freight, usually about $100 and the pressure washer kit for Predator/Honda/clones off Ebay/Amazon and have a go. thatd probably save about $150.
You actually don't need a CNC to cut with waterjet, but someway to mount the cutting nozzle on a sliding tube/rail type frame comes to mind (X or XY like an Etch a Sketch if you like)
Thanks for the vid! I totally forgot about waterjet cutting
I have one of those round galvanized steel tubs in the shop on a furniture dolly. I set a used radiator over the top and wash large parts like transmissions on it.
great stuff, a project that would go well with this is to attach a multiplying photograph mechanism to the CNC bed. WIll allow bigger cut envelopes than the mill tables envelope.
Very impressive to see what you can do for relatively little money and with just a standard pressure washer. I wonder how this would work the the Evolution modular system, then you can use the motor for other applications and make it pay for itself even more.
You are the best. Really cool project, and nice to hear about the status of the older and future ones.
Great video! I would love to see an update using stainless steel at least .048" thickness.
Really looking forward to see the super high pressure project... thanks for the video it was very educational, I really appreciate the fact that one don't have to spend tents of thousands to do water jet projects...
hehe, I also have like 50 projects in backburner, none of them are nearly as fancy as yours though...
keep it up Ben
always nice to see the process and other maker's approach
producing easy to watch content, clear and purposeful
Wow, that's great!
Most unloaders are already running slightly in bypass. You can adjust the unloader to run more bypass during operation to better match your orfice size, there are tutorials online about doing this.
Applied Science, this is very awesome. I have had thoughts of doing a laser cutter. Now I would going to use an array of diodes run to fiber optics and then use that to send down to a focusing lens. This way you can add more diodes to get more power. Just a thought
Was I the only who heard "Bridge port milling machine" and instantly thought of AvE?
Not Clapped out =/= AvE
Yep
AvE has nothing on this guy
The Bridgeport is just a milling machine. Probably one of the most common and definitely the most well known. AvE is not the only guy in the world that owns one and/or talks about it, and if you associate it that much with him I can only think that you're not very familiar with the trade.
I really like AvE, but seeing all the fangirling around him (and comments like this one, that bring his name up however unrelated the context or insubstantial the connection) makes me wonder if his audience is mostly made up of 12-year-olds only interested in dick jokes and feeling part of a group.
@@BEdmonson85 BS, AvE is obviously more intelligent, well spoken, and a FUCKING BADASS. This dude is intelligent and does good work. GG
I don't think re using garnet is a massive problem from the size of the particles point of view. I would bet you could use it a least twice and probably a lot more before this became your show stopper. I'm thinking the problem is how to recycle the used stuff. For example drying it is a big problem and without it being perfectly dry it will clog a gravity fed system like this pretty much immediately. I'm wondering if you could use a gravity feed system but leave it watered and use air to keep the garnet in supervention?
Also I know you can't use silica in shot blasters due to the dust causing silicosis if inhaled but in a system like a water jet cutter these never get airborne so would a cheaper sand work for the home hobbyist ? It may take linger but is considerably cheaper than garnet..
I'd love to do my own experiments with this and I already have the same pressure washer as used in this video. Unfortunately I'm not in the position to fork out £300 on getting the head parts. If someone has a secondhand one for sale or wants to loan one to me to further this very interesting topic then get in touch..
Never been so excited to see some science.
was their water in the bucket when you cut the hole?
or in other words, how deep does the water have to be, to slow the abrasive down enough, that its not harmful any more?
Commercial water jet machines tend to have an adjustable water level in the bed and keep the nozzle under water while working. This cuts down on noise and water spray emissions.
I'm going to wear eye protection when you post the ultra high pressure video.
Triple A rating, Amazing, Amusing and Awesome.
You can buy the pump alone (with no motor), 5kW is not that unrealistic to run a in normal house, probably even in the US.
You'd not only cut down on the noise, the operating cost would be less, there'd be less mechanical things to break and you could have a VFD regulate the speed of the motor automatically to keep the pressure valve happy.
Looking forward to the upcoming projects.
I do a lot of work on pressure washers, you should not assume your flow rate is nearly as high as the machine was advertised. The restriction created by the smaller orifice will reduced the flow rate significantly. Also the machine you showed in the video doesn't appear to have the power or a large enough pump for 4.5 gpm @3100psi, its probably more like 1.9-3gpm. Check the nozzles that came with the unit, they have a number on them that represents their spray pattern angle and gpm rating. The manufacturer uses that flow rate to set the unloader pressure.
amazing DIY project here! ... and i cant wait for that extremely high pressure chamber!
At least most science channel doesn't do clickbait:) 2018 is coming!
seek positivity everyday!
Thanks for a great video. Also, I love the fact that you poke into all kinds of interesting areas. I do too.
You can stop the edge from frosting by getting the head closer to the work-piece..and fill your bucket half way with water to stop it from piercing thru..
To avoid blasting through the sump add several layers of ball bearings they will effectively dissipate jet.
that huge bolt to the side gives me sweaty palms :3
Payoff at end of video, aww yisss :3
When I first read the title, I assumed the pressure was going to be provided by pressurized gas
maybe adding some sand on the bottom of the bucket willl help avoiding it to be cut since the sand will act as sandbox.
Better off adding 3-4" of water as the water wont be dispersed as easily as the sand and water is cheaper
*Wohooo! Intro is great Ben!:D*
one of thE very best channels of its kind !
I love this channel! It is awesome that you got this working as well as you did with commodity parts. No slight to you at all, but the final performance pretty much convinces me that a high-pressure pump is probably going to be desirable for all but the lightest applications. I guess I'm also a bit surprised you didn't mention Wazer or comment on their approach, pressures, or performance a little bit for comparison.
Curtis Layton Thanks. I mentioned Wazer in the last video, and when I researched it, they had not published their pressure or flow rate or other details. It runs off 15A 120V, so input power is known. Higher pressure is always better. It's just a question of how much you're willing to pay.
That new intro is slick! Loved seeing it on twitter!
Project update request: what's your favorite cookie recipe?
great video, appreciate the follow up on the first one. also your cost breakdown was very informative. great content
Are you ever going to do a follow-up video of your high-pressure hydraulic pump press?
Hahaha, thanks for the mental image of you running around with towels and Benny Hill blaring in the background :D
Anyway, jokes aside, awesome followup and I really want to build a water jet too. Just needs something else than a gasoline power and I'm not buying a cheapo 100 pesos washer either. Have to gobble something from a proper motor and a proper pump.
Actually, I already know the perfect water pump capable of delivering 16 MPa and having a bypass in it: Drill EDM pump. It is meant to pump water and usually powered by an electric motor. I think Alibaba had these for a couple of hundred squirrels.
What an absolute legend
My work study in college is with an advanced material processing lab, and one of the tools that is at the labs disposal is a water jet cutter(I don't expect to be using it, but it is a really impressive machine)
Looking forward to the pressure chamber experiments and the finished ruby laser
Love your channel. Concise and very informative.
I've got three gas pressure washers, all 5 hp Hondas. Looks like I need to get busy.
I wonder if you agitated the waste water and waste garnet if you could pump them back up into the orifice and real-time recycle them. You could also add fresh garnet with the used to drastically reduce your fresh garnet flow rate and cutting cost/inch. A kickstarter kit that used a modified 3d printer and your custom nozzle would have some interesting possibilities. The buyer could supply their own pressure washer locally.
What about reusing the abrasive?
The abrasive will be contaminated but it should be possible to filter out by density, like gold panning.
hey nice hope you have a good new year and thanks for another vid this year
Can the CNC modulate the jet? (I.e. if you want to cut multiple pierced holes in a piece)
CNC could switch the pump on/off, but the question that separate a proof of concept and being useful is:
How good is it, at piercing the material before cutting?
Not yet! Drilling a hole with a waterjet is possible but not easy. Modern commercial waterjet machines are sometimes equipped with a tilting nozzle that lets the water stream hit the surface and be reflected at an angle while it drills into solid stock. Applying the waterjet at a fixed 90* to the surface in order to create a hole sometimes works, but it can warp or crack the stock because the jet is so forceful. I've certainly lost ceramic parts when trying to pierce them, even on high-end machines. For a home shop waterjet, I'd strongly recommend drilling starter holes if you are doing internal cutouts. Then, you can position the nozzle, and open the valve manually to start the cut.
Water-jet, Oxy/Acet, Plasma....no matter the process, piercing is very hard on the consumables, and can (as you stated) damage the work piece....so...if you can tilt the cutting nozzle...better!
if i can "pull a trigger " and operate a pressure washer, I am sure you can figure that out....
It looks as if he just clamped the tubing rig to the edge of the cnc table. If I'm correctly seeing what he's done, the tubing rig is an upside down L-shape where the L's stem holds the cutting part and the flat is clamped to the CNC table. The whole rig is wrapped in plastic to keep the cnc mill dry. @appliedscience Could you comment if that's your setup?
How nice to see you uploaded a video.. thanks jack for the intro
Gas-powered stick. Never runs outta gas.
Thank you so much for sharing your water jet experiment. I have some salvaged linear slides and someone was throwing out a working Honda pressure washer.. so thinking this might be fun winter time project. What do you think about a stock tank with some small, roundish pea gravel under water for a basin on a water jet cutter? I've also got an older Staubli 6 axis robot which would allow very complex cutting paths. Could be interesting. Might be a great tool for roughing out stone sculptures.
Very cool project! You could use the mpcnc for your CNC frame.
You bring great material to UA-cam!
Love the logo animation
our god has returned