High cutting performance at low pressure with Water Abrasive Suspension

23.04.2021

With the innovative ConSus abrasive mixing unit, waterjet cutting specialist ConSus ANT enables the stationary use of Water Abrasive Suspension (WAS) systems in the processing industry. A continuous suspension jet provides a more efficient cutting performance at lower pressure compared to conventional Water Abrasive Injection (WAIS) systems. For easy, customisable performance comparison of both methods, a free web app is offered.

Photo Consus ANT: The ConSus (Continuous Suspension) abrasive mixing unit for the use of the WAS procedure in the processing industry.

In many industries, materials research regularly develops new materials for which suitable machining processes must be found. For a large number of materials waterjet cutting with WAS proves to be technically superior and economically more profitable than conventional cutting techniques. Compared to WAIS, the ConSus suspension jet operates at less than half the pressure and up to three times as fast. The user receives thin kerfs without hardening or material deformation. ConSus demonstrates its strengths particularly at increased cutting depths.

Suspension process convinces with higher efficiency

In contrast to three-phase WAIS systems with water, abrasive and air, the ConSus WAS system operates with a two-phase cutting jet of water and abrasive having a precisely adjustable flow rate. ConSus applies high pressure to the suspension before it reaches the remotely handled cutting nozzle. The high level of energy creates a cutting jet that emerges at almost twice the speed of sound. Its efficiency is much higher than that of the injection process, where turbulent mixing losses occur due to the contained air. The more focused WAS jet cuts precisely through even the hardest materials. That way, material with a thickness up to 1000 mm can be cut, while still maintaining a very good surface structure.

Photo ConSus ANT: The WAS cutting jet generated with ConSus reaches almost twice the speed of sound.

Less energy consumption, wear and emissions

ConSus operates at a maximum pressure of 1500 bar, even at enormous material thicknesses, which significantly reduces energy consumption and component wear. Due to a worldwide patented airlock process, ConSus also offers advantages in terms of work safety: Studies by the Fraunhofer Institute for Production Technology confirm that, even at maximum working pressure (1500 bar), noise levels are around 70 percent lower than an injection jet operating at 5000 bar. Low system pressures and high abrasive loadings, which are characteristic of ConSus, also reduce the emission of solid particles by up to 50 percent.

Photo ConSus ANT: Different materials such as construction steel can be cut quickly and precisely with ConSus.

Quick comparison of WAIS and WAS with the web app

ConSus can be integrated into any existing waterjet cutting system, whereby only the pump and control system need to be adapted. With no air or heat influence, it can be operated both above and below water. Performance and costs of WAS with ConSus as well as WAIS can be conveniently compared using a free progressive web application. All relevant data, such as the type and thickness of the material that needs to be processed, as well as the required cut quality and calculation basis, can be easily customized. The application can be accessed on the Internet via smartphone, tablet or desktop PC in German and English. The feed rates of WAS with ConSus as well as WAIS with the same hydraulic power and cutting quality are also illustrated with a video using the example of aluminum with 100 mm material thickness: https://youtu.be/F3UH_3Bk7Z8

Photo ConSus ANT: The ConSus Calc a Cut Waterjet Calculator enables a convenient comparison of WAS performance and costs with ConSus and WAIS.

The ConSus Calc a Cut Waterjet Calculator can be accessed at: https://waterjet-calculator.consus-gmbh.com/

More information at https://www.consus-gmbh.com/.