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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.

Describes how a robot simulation software package was used to perform the simulation, calibration and Off‐line programming of a waterjet‐cutting workcell, used for cutting pelts. The workcell consisting of a robot using an RJ controller and the TP robot language had to cut four parts from one pelt. Describes the difficulties encountered using manual programming and how the robot simulation package solved the problems of accuracy and repeatability. Concludes that parts were cut to a higher accuracy and programming time was drastically reduced using the simulation software.

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.