Waterjet cutting technology has revolutionized the manufacturing industry, providing a versatile and precise method for cutting a wide range of materials. 3-axis waterjet cutting involves moving the cutting head along the X, Y, and Z axes to create two-dimensional cuts.

On the other hand, 5 axis waterjet cutting adds two additional axes of movement, allowing for more complex cuts and greater flexibility in shaping the material.

In this article, we will introduce the concepts of 3-axis and 5 axis waterjet cutting and compare their differences to help you choose the suitable method for your project.

3-Axis Waterjet Cutting

Before diving into the comparison between 3-axis and 5-axis waterjet cutters, let’s talk about what a 3-axis waterjet cutter is, its working method, advantages, limitations, and its various applications:

Definition And Introduction Of The Principle

Waterjet cutting is a powerful and versatile technology that uses a high-pressure stream of water mixed with abrasive particles to cut through various materials.

A 3-axis waterjet cutting machine can control the movement of the cutting head along three different directions: X, Y, and Z.

Analysis Of Working Methods And Characteristics

The X-axis corresponds to the horizontal movement of the cutting head from left to right on the worktable. The Y-axis corresponds to the vertical movement of the cutting head from top to bottom on the worktable. The Z-axis corresponds to the cutting head’s depth from the work table’s surface.

Advantages And Limitations Of 3-Axis Waterjet Cutting

Now that you know about what is a 3-axis waterjet cutter and its working method, let’s talk about its advantages and limitations:

Πλεονεκτήματα

The following are the advantages of a 3-axis waterjet cutting machine:

• Cost-Effective: 3-axis CNC machines are more affordable than their 5-axis counterparts.
• Easy to Operate: These machines are easy to operate and do not require any specialized training. Their simple programming makes them suitable for small to medium-sized organizations.
• Low Maintenance: With fewer moving components, 3-axis CNC machines are easier to maintain and less prone to wear and tear than 5-axis CNC machines.
• High Accuracy: The precise and accurate components produced by a 3-axis CNC machine have many applications.

Limitations

The following are the limitations of a 3-axis waterjet cutting machine:

• Limited Capability: Since there is no way to rotate the workpiece automatically, 3-axis machines can only strike from certain angles. They work well when creating pieces with basic geometry.
• Limited Efficiency: These machines require multiple setups to create complex items, making them less efficient than 5-axis CNC machines.

Practical Application Cases Or Industry Examples

3-axis waterjet cutters are widely used in various industries for efficient cutting. The following are some of the practical application cases of a 3-axis waterjet cutter:

Cutting Metal

3-axis water jet technology can cut any metal, including titanium, brass, copper, hardened tool steel, aluminum, and other unusual metals. Since water jet cutting does not raise the temperature of the workpiece, its structural and chemical integrity is not compromised.

Cutting Glass

Due to its fragility, cutting glass using traditional methods can cause it to break quickly. This is why water jet cutting is one of the most commonly used cutting techniques for glass. Even complex cut patterns can be applied to a piece of glass using 3-axis waterjet cutters.

It is used to create holes in splashbacks, cutouts, frameless showers, and glass architectural applications. Many appropriate handling tools are also available for cutting glass with a water jet cutter, making loading and unloading the finished product easier.

Cutting Stones & Tiles

Granite, marble, Dekton, Caesarstone, porcelain, neolith, stone, ceramics, and tiles can all be precisely cut using abrasives added to 3-axis water jet cutting equipment.

Plastics

The use of high-temperature tools on plastics causes the release of hazardous gases. Since there is no temperature increase during water jet cutting, it is the safest method for cutting polymers.

Ceramics

Ceramics require costly saw blades and are difficult to manufacture due to their durability. For this reason, water jet cutting proves to be a less expensive cutting method for ceramics.

Textiles

Textiles readily catch fire due to their high flammability with any increase in temperature. Waterjet cutting is a cold-cutting technique, making it a popular choice in textile processing facilities.

Rubber and Foam

Rubber emits harmful gases at high temperatures, just like plastic does. Due to its advantages for safety, manufacturers all over the globe utilize 3-axis waterjet cutting to produce rubber.

5-Axis Waterjet Cutting

You now know about a 3-axis waterjet cutter. Now let us talk about what a 5-axis waterjet cutter is, its working method, advantages, limitations, and its various applications:

Definition And Principle

A 5-axis CNC machine can operate along five different axes of motion. In addition to moving along the three linear axes (X, Y, and Z), it can rotate about the other two axes (A and B). This increased range of motion allows the machine to produce complex shapes.

Working Method And Characteristics Analysis

In 5-axis waterjet cutting, the cutting head can move along five axes, including the three conventional axes and two additional axes:

X-axis: The cutting carriage travels horizontally (left to right) in the direction of the cross beam.

Y-axis: The cutting head is moved back and forth (front-back) along the side beams by the cross beam.

Z-axis: The vertical (up-down) movement of the cutting head.

A-axis: A cutting angle of up to 60 degrees can be achieved by tilting the cutting head. This allows for angled cutting, which can create bevels and various shapes.

C-axis: By rotating the cutting head around the Z-axis, various shapes can be cut.

Advantages And Limitations Of 5-Axis Waterjet Cutting

Now that you know about what is a 5-axis waterjet cutter and its working method, let us talk about its advantages and limitations:

Πλεονεκτήματα

The following are the advantages of a 5-axis waterjet cutting machine:

• Better Accuracy: By allowing the cutting tool to move along five axes, they can produce parts with better surface finishes and greater accuracy.
• Reduced Tool Changes: Continuous milling processes enable the creation of complex shapes, resulting in fewer tool changes. This saves time and reduces the need for human intervention.
• Efficiency Gains: 5-axis machines can speed up production while improving efficiency. In addition to performing continuous machining operations, they can create complex shapes.
• Versatility: Five-axis machines can produce a wide range of parts and shapes.

Limitations

The following are the limitations of a 5-axis waterjet cutting machine:

• Maintenance: Regular maintenance is required to keep these sophisticated machines in good working order and prevent malfunctions.
• Training: Due to their complexity, they require more specialized education and training to operate and maintain.
• Cost: Due to their higher price than 3-axis CNC machines, 5-axis CNC machines may be more difficult for smaller companies.

Practical Application Cases Or Industry Examples

5-axis waterjet cutting has also established itself as an essential manufacturing technology across several industries. Some of these industries include:

Prototyping

Waterjet cutting machines are often used to produce prototypes for models in the R&D industry. The creation of prototypes provides a detailed model that takes scale into consideration. This is advantageous because 5-axis cutting heads can produce intricate shapes.

Automotive

In the automotive industry, 3D spare parts for automobiles, such as different gears and engine parts, are produced using 5-axis waterjet cutting. The key advantage is that both small and large components can be easily produced using this technology.

Αεροδιαστημική

The aerospace industry requires very precise cutting to produce 3D components for space equipment. Some of the strongest metallic substances, fibers, and alloys are among the materials that can be cut.

5-axis waterjet cutting is the best technology for this sector as it can cut through the toughest materials and produce very accurate 3D parts.

Manufacturing Workshops

Fabricators often use 5-axis cutting machines for weld preparation and other cutting needs. Any project you work on is likely to use components that were cut using a waterjet 5-axis cutter.

Décor

Three-dimensional artworks made of various materials are also created with this technique for use as décor. The use of art waterjet is prevalent in the fields of architecture and interior design for aesthetic reasons.

Compare And Differentiate Between 3-Axis And 5-Axis Waterjet Cutting

As you see, both 3-axis and 5-axis waterjet cutter has their own working mechanism, advantages, limitations, and specific applications. Now we will compare them in detail:

Cutting Accuracy And Speed Comparison

With the addition of extra axes, the cutting head can travel further. This allows for high-speed cutting operations, as the head is no longer limited to linear movements and can reach the furthest point in the shortest amount of time.

3-axis waterjet cutters may experience delays due to the secondary procedures they must perform for various tasks. However, these tasks are completed by the waterjet cutter in 5-axis waterjet cutting.

Ability To Cut Complex Shapes

The A-axis and C-axis provide taper control for complex cutting angles when creating bevels and chamfers, expanding the possibilities of 5-axis waterjet cutting.

Cutting Cost And Efficiency Comparison

Metal components undergo pre-welding operations such as chamfering and beveling to prepare them for joining together. These pieces require manual effort to prepare them for welding. 

However, finished components from 5-axis waterjet cutting leave the machine ready for welding, significantly reducing the need for physical labor.

The prices for 3-axis CNC machines can vary from $25,000 to $50,000, while those for 5-axis machines can range from $80,000 to over $500,000. The costs can change depending on whether you will use them for production-level work or entry-level jobs.

Comparison Of Application Scenarios And Applicable Industries

Firstly, anything that a 3-axis waterjet cutter can accomplish can also be achieved by a 5-axis waterjet cutter. However, 5-axis waterjet cutters can perform several tasks that 3-axis waterjet cutters cannot.

5-axis waterjet cutting can produce linear cuts in both two and three dimensions, while only two-dimensional linear cuts are possible with 3-axis waterjet cutting.

Συμπέρασμα

In this article, we have introduced 3-axis and 5-axis CNC machining, describing their differences, advantages, and disadvantages. 3-axis CNC machining is suitable for simpler parts with less complex geometries, while 5-axis CNC machining is capable of producing more intricate parts with greater precision.

When selecting between the two, it is important to consider the specific application scenarios and requirements. If you need further advice on which type of CNC machining is best for your project, don’t hesitate to επικοινωνήστε μαζί μας.