Gas-powered waterjet cutter (follow-up) and other project updates-----make money online

today on Applied Science I'm going to do

a follow up on my water jet cutter built

from a low-cost pressure washer idea so

in a previous video I showed how you

could take a hundred and thirty dollar

electric pressure washer and connect it

up to a water jet nozzle and actually

get halfway decent results out of it but

as it turns out that was pretty much a

proof of concept only since the electric

motor overheated and the pump developed

leaks and it wasn't really going to

continue cutting at this let the level

of performance that I showed in the

video so today I'm going to show what

happens if you take a gasoline powered

pressure jet or pressure washer and

connect it up to a water jet nozzle and

see what we can get so you can see here

the results look pretty good we've got

an aluminum sample here and these edges

are completely unaltered I haven't

smooth them at all so this is directly

off the machine and then you can see a

acrylic sample you can see that the cut

quality is pretty good it's um it's a

really 90 degrees to the surface

everything is great and then the

material that everyone wants to cut with

water jet cutter glass this one also

came out quite nice you can see if you

look carefully there's a little bit of

frosting on the flat surface of the

glass and that's from the abrasive

getting thrown around and actually

fogging the glass a little bit and then

there's a little bit of an offset in the

cut which wasn't the machines fault I

just bumped it and got the XY offset a

little bit also I found out this machine

can cut steel a little bit by accident

you can see the bucket that I was using

as a galvanized steel tub to hold all

the water that comes out of this and

during cutting it developed a leak in

fact the machine was powerful enough to

punch a hole in the bucket from a good

foot away very much to my surprise and

even more than that the machine

continued boring a hole into the

concrete floor of my garage where the

bucket was sitting so if I was good at

doing comedy and videos I would have

showed you trying to bail out my garage

with towels and buckets and eventually a

wet/dry vac that eventually got the cut

done and got the bucket out of there I

wanted to find a solution for this DIY

water jet cutter project that would

involve as few modifications as possible

to the pressure washer

and in this case no modifications and so

I'm using a $300 delivered gasoline

powered pressure washer from Amazon and

there's no modifications to it

whatsoever it's completely stock I take

the hose right from the pressure washer

and connect it right up to this nozzle

system which I'll show in a minute the

operation of the system is pretty

straightforward basically just start the

motor up and the pressure will rise and

then open the valve which you don't even

really need to let the high-pressure

water out the nozzle add the abrasive

flow to make sure that the make sure the

water is flowing before the abrasive is

added and then once everything is

flowing you can start the CNC machine to

move the nozzle over the workpiece just

a couple of you know slight problems you

might run into one is that the pressure

washer has a built-in unloader valve

which I talked about in the previous

video too and the point of this is that

when you're actually using it as a

normal pressure washer when you let off

the trigger and you want the water to

stop flowing the water has to go

somewhere and so there's a valve in the

pressure washer that bypasses it

bypasses the output and it lets the

water recirculate and in this case we're

using an orifice that's a little bit

smaller than the one that comes with the

stock pressure washer wand and so the

valve the unloader valve and the

pressure washer can sometimes cycle

between bypass and flow because we're

really pushing it right up to the top

limit and so the machine is kind of

unsure if it's supposed to be in

bypassed or not so anyway so the way to

fix that is to just you know add a

little bit more spring pressure to the

valve or set the pressure to be ever so

slightly higher or use a bigger orifice

on the water jet nozzle side I found

that just using a pair of channel locks

and just squeezing the unloader valve

very slightly was enough to get the

system flowing and once it was flowing

smoothly it never went back into that

oscillatory phase overall the system is

pretty well behaved honestly as long as

the cut is going all the way through and

the water jet is making it down into the

bucket there's not a whole lot of

splashing I mean it gets a little bit

messy it's not too crazy though the

problems arise if you try to cut too

quickly and the water jet doesn't make

it all the way through the material then

you get this you know big pretty big

spray cloud to come

out of there and that's that's

unpleasant to deal with so better slow

than sorry is basically what it comes

out to there's sort of no penalty for

going slow other than spending a little

bit more money on garnet which we'll

talk about in a minute but the penalty

for going fast is a pretty big mess

also the penalty for having your bucket

get torn up by the jet and having it

flood your garage is also pretty

self-explanatory there

the precision is quite good as you might

imagine the the jet is constant and so

the real determination of how Square and

smooth and everything will be is how

rigid your setup and how good the CNC

machine is itself and in this case I'm

already within about 1% of length across

this just from a real estimation I think

I estimated the kerf to be about one

millimeter and just put that into fusion

360 and used its built-in cam feature to

generate the g-code and it's really good

the straight lines come out really

straight so even though the system isn't

incredibly rigid it's it's good enough

and as we found out it's actually quite

workable the milling machine that I'm

using is an old Bridgeport that's been

upgraded so it's control is completely

modern but it has the original motors

and all the original iron is there now

obviously a lot of people don't have a

Bridgeport milling machine in their

garage but that's that's ok there's

plenty of CNC machines on eBay that are

small and aren't particularly strong

like you would have a tough time milling

steel on them but it's actually a great

fit for water jet cutting because the

cutting forces are so low you almost

don't need any clamping at all you do

actually need to hold the work down it's

not quite like a laser cutter but the

cutting forces are pretty minimal so if

you get one of these small you know $500

CNC machines off eBay there's a really

good chance that would be more than good

enough to do a waterjet cut ok let's

take a look at the stats and the costs

for this system and this column is the

electric water jet cutter from the last

video and then in this column is the

gasoline-powered system that you saw

today and this is considering the system

when it was sort of overclocked and so

this electric pressure washer was

designed to run at about 15 amps at 124

but if you provide a flow restriction

and then also play around with its off

loader valve or unloader valve you can

get you can get the motor to draw a more

current because it keeps trying to run

at the same speed so I actually got it

up to about 20 amps at 128 volts so 2.4

kilowatt I didn't measure the flow rate

but the commercial SPECT flow rate is

1.7 gallons per minute and the pressure

is higher because of the additional

power that we're putting into it the

flow rate could be a little bit less

than this though because this is the the

rated flow rate for its original

pressure but anyway it's probably pretty

close I was using an orifice of 18,000

at in order to get this flow rate at

this pressure

hey the gasoline machine has quite a bit

more power four-and-a-half kilowatts I

mean it's just hard to beat chemical

energy storage and we're getting 3100

psi at 2.8 gallons per minute so

remember the the thing that's doing the

cutting in these water jet cutters is

the particles of sand garnet that

they're coming out at high speed and so

the amount of energy in each particle

1/2 MV squared means that the faster

they're going the more energy they have

and sort of the more efficient at

cutting they are so the reason that

these water jet cutters use such a high

pressures because they want those

particles of garnet going really fast

because you get a V squared term so you

get much more energy for putting in more

speed or more pressure but if you can't

have more pressure because it's

expensive and difficult to get

high-pressure water what you can do is

make up for it by just having a lot more

mass you don't get the squared term so

you don't get that sort of multiplier

effect but if it's so much cheaper to

get a higher mass flow rate you can win

that way so 30 100 at 2.8 gallons per

minute is still going to cut faster than

3200 at 1.7 for sure in order to get the

higher flow rate at the same pressure we

use a slightly larger orifice in the

water jet cutting nozzle head now

luckily these orifices are available in

like 2000 chromatic 4th ow up to pretty

big maybe 40 or something like that and

they're not very expensive so you can

buy a few and try different sizes out if

your custom

building a system the focusing tube is

the thing looks like a nozzle that comes

out the bottom of the water jet cutting

system and the trick here is that it

works sort of like a rifle barrel where

the high-pressure high-speed water comes

in this side along with the garnet and

then as it's moving down the tube it's

the garnet is picking up speed because

it's being pushed by the water and when

it comes out the end it's going really

fast and cuts your material the trick is

that you want this to be sized in

relation to the orifice so imagine if

you're squirting water into it from the

top you don't want to be squirting it

with a really large jet of water because

it's going to hit the sides and sort of

overload the focusing tube and

conversely you don't want too small of

an orifice here because it would sort of

this stream wouldn't fill the tube up

very well and you would get particles

that don't accept the momentum very well

I think the conventional wisdom in the

industry is to use like a two and a half

or three to one ratio so if your orifice

is ten foul you'd want to use a 30,000 -

in this case it's not working so well

for us because they don't make these

focusing tubes in a large enough

diameter and also the cutting kerf would

be unacceptably large so remember that

you know the diameter of the hole that's

in the end of this thing determines how

big the cutting kerf is so if this is it

like you know a two millimeter diameter

it starts to be not a very great cutting

tool or Dino it's just not a really good

water jet system so anyway so I bought

the biggest one that a key stream had

which is 45 fowl so we're not even quite

double this but you know the thing works

I'm not having any problems with it so

if you follow the same setup that I have

here you should get pretty good results

next is the abrasive flow rate remember

it's actually the garnet the sand that

does the cutting in a water jet system

like this and so this is a pretty

critical element if your abrasive flow

rate is zero then your cutting speed is

zero and if you add more and more

abrasive you get faster and faster cut

rate until the stream is completely

saturated with garnet and there isn't

really enough water to do that momentum

transfer in the focusing tube so there

is sort of a an optimal value there

and I haven't done a lot of

experimenting to find out what it is but

I know that point four pounds per minute

works fairly well and I was using the

same value for my gasoline-powered

system today but I have a feeling that

you could turn this up quite a bit

higher I mean in theory it's not quite

double the water flow rate but maybe

it's you know 50 percent higher so you

could probably get a much higher

abrasive flow rate and hence a faster

cutting speed so in sixteenth inch

aluminum I was getting maybe two inches

a minute with the electric system and I

could easily get two inches per minute

like it was much easier to start cuts

and you know enter the material and

things like that whereas with the the

older system two inches per minute may

have been a little optimistic maybe but

I think it's pretty comfortable for this

one unlike most other shop tools the

cost of the abrasive is actually

something to really consider it's about

a dollar a pound delivered from an ebay

source and if you do all the math you

know two inches a minute 4.4 pounds per

minute it comes out to about 20 cents

per inch in 16-inch aluminum and if

you're cutting a really thick material

it's going to be much higher because

your cutting speeds going to be slower

and so you're going to need more

abrasive per you know linear inch of cut

really something to consider what you

can do is get started with fusion 360

and just check how long your tool paths

are you might be surprised you know if

you're just cutting plain old circles

out you know that's not so bad if you're

cutting something intricate like a

sprocket or something like that

all those little holes and you know

teeth add up and you might be surprised

how expensive it is to cut things out

generally this is why the industry only

uses water jet for pretty demanding

operations like if you're cutting carbon

fiber glass or ceramic or something

really hard that you just can't cut any

other way

that's when water jet really shines so

just sort of a quick cost recap the

gasoline powered pressure washer is 300

bucks delivered the cutting head it is

just a chunk of metal but the tolerances

are pretty tight so you could definitely

make this yourself but it's it would be

quite a a pretty decent machining job

there

300 bucks the focusing tube this one

would be tough to make yourself because

the tube itself is made out of tungsten

carbide it's a really really hard

material I'd recommend just buying that

85 bucks and the orifice 15 so what do

we have to hear 400 700 for this and

then if you want to get a CNC machine

there's certain I haven't tried them

myself there's plenty of like tabletop

size CNC machines on eBay for the 5 in

the 5 to $600 range so you know you're

you're definitely under 1,500 to get a

very serviceable water jet cutter which

is pretty cool and since the

gasoline-powered machine is operating

completely within its normal guidelines

I would expect you know a fairly decent

lifetime out of it this one was really

the electric was really really

overclocked III don't think I'd

recommend that one just a couple of last

points if you do this with the AK you

stop part doesn't really come with

anything because this is expected to be

connected to like a commercial water jet

machine so what I did was just got a

standard stainless bolt from McMaster

and drilled a hole through it that was

big enough to accept this stainless tube

and then cut a countersink into the end

here that matches the taper that's on

the end of the orifice so this thing is

has a cone on the top here I forget what

the exact angle is but I basically cut

this on the lathe to match the angle

here so that when you shove this in here

this makes a good watertight seal and it

all comes together like this and so the

orifice goes in there with the cone

facing up and then this goes in here and

y'all tighten it down and you'd be

surprised how well all this works

leaking is really not much of a problem

and it doesn't take a lot of torque to

get these things to seat also the the

gauge in the valve are completely not

necessary they do make the whole system

a little bit easier to tune and control

but they are expensive and you really

don't need them if I were going to build

the system and I was mostly just

interesting

interested in getting a working cutter I

would just do this get one of these high

pressure pressure washer couplers which

is an easy item you can get on Amazon

and then just braise or weld in a tube

that fits into the back of that cutting

head and you can probably come up with

even a better way of doing this than I

did that just put a bunch of like

braised in there you might be scared of

3000 psi but it's actually not that bad

and you've got a lot of surface area to

braise this together it won't come apart

at 3,000 for sure I thought I'd give you

a couple of quick project updates as

well for the Tesla CANbus data logger

in-car display system I'm kind of

waiting on the Tesla car browser to be

upgraded it's really slow and even

though it works with WebSockets I'm not

able to do superfast update real time

graphing which is kind of the whole

point of the system and Tesla keeps

saying that they're going to issue an

update that will make the browser better

but it hasn't happened yet and it hasn't

been a super high priority but when they

come out with the browser update that'll

be a good like motivation for me to to

get the data logger project going the

Ruby laser is still waiting for the Ruby

rhod to have its ends polished there's

still some damage there from the last

time I was using it but this was

definitely gonna happen you know sooner

than later I think I am gonna redesign

the way that that whole cooling jacket

works since that was responsible for

this thing getting torn up the last time

but it is pretty cool and I didn't get a

chance to do lunar moonbounce which is

the whole point of building this thing

among other you know - popping holes in

metal but anyway this one will be coming

along - and then most excitingly I've

been working on this ultra high pressure

chamber actually for a long time but

we're getting pretty close now so we've

got a hydraulic ram that's going to be

forcing liquid into a chamber at you

know hopefully a hundred thousand psi or

something like that we're gonna see how

high we can get and a lot of weird

experiments you can do at ultra high

fluid pressure okay see you next time

bye

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