The waterjet cutting heads from KMT Waterjet Systems offer maximum efficiency and value for money. They are in use on a daily basis all over the world in many different waterjet applications. The innovative design of the individual components and the construction from durable materials ensure long service life and minimium maintenance. KMT Waterjet Systems offers four cutting head models for pure water and abrasive cutting that can be easily integrated into any waterjet cutting machine.
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High Speed, self-aligning Cutting Nozzle
Further development of tried and tested cutting heads
The new AUTOLINE™ II abrasive cutting head combines the reliability of the original model with a number of innovations that make waterjet cutting even more efficient and userfriendly. Old cutting heads can be replaced quickly and easily. ACTIVE AUTOLINE™ II systems can be integrated into all waterjet units, be it 2D units, multi-axle machines or robot systems.
Optimised abrasive feed
The abrasive material is fed through a wear-proof cemented hard metal tube at an angle of 30° to the mixing chamber. This reduces the need for space and prolongs the service life of the nozzle body and insert. The mixing chamber has been repositioned to allow for better access for the cleaning and replacement of the nozzle insert. A pin ensures proper alignment of the mixing chamber and the abrasive inlet at the nozzle body, so that flow loss caused by incorrect installation is effectively prevented. The orifice is mounted directly on the mixing chamber.
Design ensures correct alignment of the jet
There is no need to adjust the water jet alignment at the nozzle. The construction design ensures that the water-abrasive mixture is ejected at the centre of the nozzle and at maximum speed. The centred and powerful waterjet is one of the key features of all AUTOLINE cutting heads.
Ergonomic handling of focusing nozzle
The installation and removal of the focusing nozzle has been made even more user-friendly. Thanks to the wing screws, it can be properly mounted without the need for tools.
Instant indication of preventable faults
The cutting head is now equipped with a leakage bore near the water nozzle. It indicates whether the nozzle is installed correctly and the cutting head is properly secured. Damage to the sealing surfaces of diamond or sapphire nozzles or to the nozzle pipe can thus be easily detected and eliminated.
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Breakthrough in Performance and Simplicity
The ACTIVE IDE™ II sets new standards for abrasive waterjet cutting heads! The cutting head contains a minimum number of individual components, is particularly easy to handle and produces high-precision cuts.
Less components – reduced maintenance
As the cutting head contains a minimum number of individual components, it is particularly easy to handle while producing high-precision cuts. The key advantages of the ACTIVE IDE™ II are the exact targeted cutting jet, the pre-filter protecting the orifice and the advanced nozzle valve design. The unit is also virtually maintenance-free. To achieve a perfect cutting jet, all you need to do is exchange the focussing tube.
The diamond orifice and the mixing chamber are combined in a single nozzle body. Both professional users and workers who have only recently been introduced to abrasive cutting benefit from the simple design of the unit, as the focussing tube and the pre-filter, which are the only wear parts, can be exchanged easily and quickly. Maintenance is thus limited to an absolute minimum.
Performance increased by ten to twenty times
The integrated diamond orifice far outperforms any sapphire orifice. The prolonged service life means longer uptime and thus more consistent and precise cutting performance. The innovative design is based on a mixing chamber where water and abrasive are mixed in a most efficient and effective way, minimising the jet stream width so that all impact energy is concentrated in the cutting tip of the jet. The result is a perfect and accurately positioned cut.
New pre-filter protects the water nozzle
The newly developed pre-filter is installed between the HD line and the nozzle valve body in the adapter. This component reduces the mechanical impact on the water nozzle, as particles are removed from the cutting jet so that they do not cause abrasion to the nozzle. This significantly prolongs the service life of the nozzle and lowers the operating costs.
Superior edge quality
Thanks to the longer service life of the diamond orifices, a more consistent water jet can be achieved over a longer period of time. This in turn helps increase the lifespan of the focussing tube and results in smoother cutting edges and less waste.
Quicker and easier changeover from pure water cutting to abrasive cutting
Operators can quickly change over from pure water cutting to abrasive cutting by simply replacing the water tube with the IDE orifice tube that fits the nozzle valve.
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Reliability proven in Three Shift Operation
Automotive applications are among the most demanding of subcontracting jobs in the industry. Demands put on waterjet components are certainly not an exception, but a confirmation of this rule. Production units usually run 3 x 8-hour shifts throughout the complete week highlighting a need for extremely high reliability and speed.
Any production stop is equivalent to expensive delays and shutdowns of processes further down the production flow stream.
Wide Range of Different Applications
Pure water cutting applications usually work with significantly higher cutting speeds compared to those of abrasive cutting. The typical applications of this nature are found in the Automotive and Aerospace Industries, as well as miscellaneous plastic and composite paneling. Gaskets, foams and food are also sizeable application areas for pure waterjets.
Reliability under extreme conditions
Our AQUALINE I pure water cutting head has gained an industry-wide reputation for being amongst the quickest and the most reliable pure water cutting heads under extreme working conditions, through fastest reaction times and high component lifetimes and quality. Applicable in 1D to Multiple Axis Systems The AQUALINE I cutting head is widely used in robotic “3DCutting Boxes” as well as multidimensional cutting machines.
High Performance Nozzle Valve
The multiple cutting cycles found in these industries place huge requirements on the on/off cycle speed and reliability of the cutting valve. The KMT WATERJET AQUALINE I provides the industry's top quality leading solution in this area. Depending on the application, normally closed (N/C) and normally open (N/O) cutting valves are available. The nozzle valve opens in less than 50 ms depending on the operating pressure.
Compact Design for Flexible Use
The AQUALINE I head weighs only 1.8 kg (3.9 lbs) guaranteeing high flexibility and making multihead and 3-D applications easy. It can be equipped with both sapphire and diamond orifices, whatever fits the individual process needs best.
The compact design allows it to be adapted to multiple cutting nozzles on a 1- or 2-D cutting machine to increase production throughput. The compactness also creates the possibility of installing a second set of cutting heads as a backup or redundant solution. In practice, oftentimes more than 12 cutting heads are hooked up to a single cutting system.
Key Focus on Maintenance Friendliness
Leak holes protect the nozzle body, nozzle tube and nozzle nut from damages and indicate clearly which connection has to be tightened or which seal has to be replaced. The unique design allows for replacing the seal in under 5 min.
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The new PRO abrasive cutting head from KMT Waterjet has been specially designed for waterjet cutting with 6,200 bar. Its design and materials can withstand huge forces while focussing the energy to the point where it is needed, namely to the cutting jet.
ACTIVE AUTOLINE™PRO-I abrasive cutting head
Among the outstanding features of ACTIVE AUTOLINE™PRO cutting heads are automatic precision positioning, perfect repetition accuracy, high cutting speeds, long service life and easy maintenance. It takes only seconds to replace the few wear parts of the head, such as the orifice, mixing chamber and focussing tube, and no tools are required. In order to keep routine maintenance to a minimum, these parts are made from tough wear-proof materials. The typical features of KMT Waterjet products based on the innovative approach for efficiency and economy in continuous operation have thus been successfully integrated into the design of the company's latest development. ACTIVE AUTOLINE™PRO cutting heads can also be integrated into all waterjet cutting systems with rigid or multiple head connections.
Improved cutting performance thanks to high precision
The diamond orifice is integrated into the orifice body. A specially devised manufacturing method ensures that the waterjet is at all times properly aligned and connected to the mixing chamber located below the orifice body. In the mixing chamber, the abrasive is added to the waterjet. The stringent production tolerances for the mounted cutting head guarantee that the cutting jet is always properly aligned along the axis. As the waterjet exits the focusing tube at the correct angle, the power of the waterjet is focused for optimum impact. This allows for maximum cutting speeds at minimum cutting gaps combined with excellent cutting edge quality.
The nozzle valve for maximum stress
The wide range of cutting tasks and numerous switching cycles puts a heavy strain on the nozzle valve. With the AQUALINE PRO pure water cutting head, KMT Waterjet has now developed the perfect solution for 6,200 bar applications. As the cutting speed is higher than with 4000 bar, delamination is significantly reduced and in many cases completely eliminated. Depending on the actual requirements, the valves are available as normally open (N/O) or usually closed (N/C) valves. These high-pressure valves usually open in less than 50 ms, depending on the operating pressure. High precision, sturdy design and extremely short switching times are the key features of the AQUALINE PRO waterjet cutting head range.