Machinery's Handbook, 31st Edition
NONTRADITIONAL MACHINING AND CUTTING 1343 Table 1. Typical Characteristics of Some Nontraditional Machining Methods Water Jet (WJM/AWJM) Laser (LBM) Plasma (PAM) Electrical Discharge (EDM/WEDM) Process Used Erosion Melting/Vaporization Melting Vaporization/Erosion Materials Processed Most Many Conductive Conductive Materials Not Processed Diamond Some Reflective Non-Conductive Non-Conductive Tempered Glass Non-Homogeneous Non-Homogeneous Non-Homogeneous Feature Detail Level High Very High Medium Very High Maximum Part Thickness (Rough Cut) 12 in. (305 mm) 1.5 in. (38.1 mm) 6 in. (152.4 mm) 12 in. (305 mm) Maximum Part Thickness (High-Quality Cut) 2 in. (50.8 mm) 1 in. (25.4 mm) 2 in. (50.8 mm) 12 in. (305 mm) Typical Accuracy (Thin Stock) ±0.001 in. (0.03 mm) ±0.001 in. (0.03 mm) ±0.01 in. (0.25 mm) ±0.001 in. (0.03 mm)
Typical Accuracy (Thick Stock) Minimum Kerf Width (Thin Stock)
±0.005 in. (0.13 mm) Pure Water: 0.003 in. (0.08 mm) Abrasive Jet: 0.015 in. (0.38 mm)
±0.005 in. (0.13 mm) ±0.03 in. (0.76 mm) 0.001 in. (0.03 mm) 0.02 in. (0.5 mm)
±0.001 in. (0.03 mm)
Wire EDM: 0.0008 in. (0.02 mm)
Typical: 0.013 in. (0.34 mm)
Cut Speed
Slow to Moderate Fast to Very Fast
Very Fast
Slow
Cut Surface Quality Cut Characteristics to be Managed Heat Affected Zone on Cut Surfaces
Very Good
Excellent
Good
Excellent
Kerf Taper, Exit Burr
Kerf Taper, Dross
Kerf Taper, Dross, Slag True to Form
None
Narrow Zone
Yes
Narrow Zone
Post-Processing Needed
Sometimes: Deburr
Sometimes: HAZ and Dross Removal
Sometimes: Stress Relieve, Straighten, Slag/ Dross/HAZ Removal
None
Wire EDM: Pre-Processing is Required to Add Pierce Holes
Table 2. Examples of Cutting Speeds for Metals
High-Quality Cut Feed Rate, in/min (mm/s)
High- Definition Plasma, 260A
Plasma Process Gas/ Shield Gas
Abrasive Waterjet 60 HP, 60 ksi
Thickness in (mm) 0.04 (1.0) 0.25 (6.4) 0.5 (12.7) 0.04 (1.0) 0.25 (6.4) 0.5 (12.7) 0.75 (19.1) 0.04 (1.0) 0.25 (6.4) 0.5 (12.7) 0.04 (1.0) 0.25 (6.4) 0.04 (1.0) 0.2 (5.0) 0.5 (12.7)
Laser Assist Gas
CO 2 Laser 4kW 420 (178)
Fiber Laser 4kW 1457 (617)
Material
225 (95) 32 (14) 14 (6) 80 (34) 10 (4) 2 (0.8) 75 (32) 11 (5) 162 (69) 23 (10) 146 (62) 3 (1) 4 (2)
—
—
Aluminum
Nitrogen
40 (17)
100 (42)
60 (25) 190 (80) 215 (91) 200 (85) 115 (49) 90 (38) 60 (25) 65 (28) —
Air/Air
— 21 (9)
H35/Nitrogen
280 (119) 100 (42) 56 (24) 33 (14) 400 (170) 80 (34)
319 (135) 110 (47) 60 (25) 33 (14) 1456 (616) 138 (58)
Carbon Steel
Oxygen
Oxygen/Air
—
Stainless Steel
Nitrogen
F5/Nitrogen H35/Nitrogen
16 (7)
39 (17)
1338 (566)
Brass
Nitrogen
N/A
N/A
N/A
42 (18)
1181 (500)
Copper
Oxygen
N/A
48 (20)
21 (9)
N/A
N/A
— 5 (2)
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