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Outlines the background of robotized waterjet cutting and its advantages over traditional punching and manual cutting methods. Discusses the development of the modular cutting box which can be adapted to the customer’s requirements covering the water pressure, the size and speed of the jet, the reduction of sound emissions and a safety zone to protect personnel. Examines the programming of the robot arm and the creation of cutting programs. Concludes that waterjet cutting has enormous potential in the automotive industry.

An extremely high‐pressure jet of water is an efficient method of cutting soft materials, and combining the waterjet process with industrial robots is an economic alternative to the traditional punch tool method of producing complex‐shaped components for car interiors, such as floor carpets, headliners and door trims. Applications are given of robotic waterjet systems installed in the USA, France and Iran as well as news of a new cutting box introduced by ABB‐IR Waterjet Systems. A further development of the waterjet process is described in which the addition of abrasives enables aluminium castings to be fettled and cleaned.

The past five years have seen a significant improvement in the reliability and the acceptance of two‐dimensional abrasive waterjet (AWJ) cutting systems. Across all of the major industrial countries in Europe, one can now find any number of job shops or custom cutting centres offering AWJ cut parts. Three‐dimensional AWJ cutting systems were first introduced into the aerospace industry. The AWJ machines used to cut aerospace parts were mainly limited to large‐frame, cost‐intensive five‐axes units dedicated to the aerospace industry. Recently, a select few of the well‐established users of two‐dimensional AWJ cutting systems have acquired three‐dimensional AWJ cutting systems. New, lower‐priced systems combined with innovative configuration options, improved programming techniques, advanced automation and accuracy have taken three‐dimensional AWJ to another level. Discusses the recent developments in three‐dimensional AWJ systems.

Waterjet cutting is finding increasing use in the aerospace and motor industries. John Mortimer reports.

A pilot project at the Ford Motor Co. plant in Genk, Belgium, uses robot‐guided waterjets to cut holes in bumpers for Sierra cars.

Chadderton, England — the home of British Aerospace PLC (BAe), the British company which plays an important role in the Airbus project as designer and builder of the wings for A300, A310, A320 and A340 aircraft. The wings are designed at BAe, Filton, prior to machining at Chadderton, following which assembly is undertaken at BAe in Chester. The company has a one‐fifth share in the Airbus business representing £1 billion turnover and with orders and deliveries for the aircraft approaching 900, the importance of Airbus to the plant is continuing to increase.