# Patent

## Title
Fluid/abrasive jet cutting arrangement

## Abstract

A high pressure cutting arrangement includes two pressurized streams: a liquid stream and a slurry stream. The two streams are independently pressurized, and then combined at pressure. The combined stream is then accelerated through a nozzle to provide a cutting jet.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a Continuation-in-Part of U.S. Ser. No. 12/674,261, filed Feb. 22, 2010 which is a 371 application of International Patent Application PCT/AU2008/001226, filed Aug. 21, 2008, which claims priority of Australian Patent Application Ser. No. 2007904499, filed Aug. 21, 2007, Australian Patent Application Ser. No. 2007904498, filed Aug. 21, 2007, and Australian Patent Application Ser. No. 2007904500, filed Aug. 21, 2007.


BACKGROUND OF THE INVENTION
The present invention relates to cutting (for instance of metals) by jets of liquid including entrained abrasive particles.
The use of high velocity water jets containing entrained abrasive particles for cutting purposes has been known since about 1980. Known cutting water jet systems fall into one of two categories: Abrasive water jet (AWJ) systems and Abrasive suspension jet (ASJ) systems.
AWJ systems typically supply water at extremely high pressure (in the order of 150 to 600 MPa) to a nozzle. A typical AWJ nozzle 10 is shown in FIG. 1. The nozzle 10 includes a small orifice 12 (0.2 to 0.4 mm diameter) which leads into a mixing chamber 14. Water thus flows through the mixing chamber 14 at a high velocity.
Small grains of abrasive material, typically garnet, are supplied to the chamber, generally by a gravity feed through a hopper 16. The high water velocity 18 creates a venturi effect, and the abrasive material is drawn into the water jet.
The water jet then flows through a length of tubing known as a focussing tube 20. The passage of water and abrasive through the focussing tube 20 acts to accelerate the abrasive particles in the direction of water flow. The focussed water jet 22 then exits through an outlet 24 of the focussing tube. The water jet 22—or, more accurately, the accelerated abrasive particles—can then be used to cut materials such as metal.
The energy losses in the nozzle 10 between the orifice 12 and the outlet 24 of the focussing tube 20 can be high. Kinetic energy of the water is lost by the need to accelerate the abrasive material, and also to accelerate air entrained by the venturi. Significant frictional losses occur in the focussing tube 20, as abrasive particles ‘bounce’ against the walls of the tube. This results in energy loss due to heat generation. As an aside, this phenomenon also results in degradation of the focussing tube 20, which typically needs replacing after about 40 hours' operation.
Known AWJ systems are therefore highly inefficient.
ASJ systems combine two fluid streams, a liquid (generally water) stream and a slurry stream. The slurry contains a suspension of abrasive particles. Both liquid streams are placed under a pressure of about 50 to 100 MPa, and are combined to form a single stream. The combined stream is forced through an orifice, typically in the order of 1.0 to 2.0 mm diameter, to produce a water jet with entrained abrasive particles.
ASJ systems do not suffer from the same inefficiencies as AWJ systems, as there is no energy loss entailed in combining the two pressurised streams. Nonetheless, known ASJ systems are of limited commercial value. This is partly because ASJ systems operate at significantly lower pressures and jet velocities than AWJ systems, limiting their ability to cut some materials.
ASJ systems also evidence significant difficulties in operation, primarily due to the presence of a pressurised abrasive slurry, and to the lack of effective means to provide control over its flow characteristics. The parts of the system involved in pumping, transporting and controlling the flow of the abrasive slurry are subject to extremely high wear rates. These wear rates increase as the pressure rises, limiting the pressure at which ASJ systems can safely operate.
Of possible greater significance are the practical difficulties inherent in starting and stopping a pressurised abrasive flow. When used for machining, for instance, a cutting water jet must be able to frequently start and stop on demand. For an ASJ system, this would require the closing of a valve against the pressurised abrasive flow. Wear rates for a valve used in such a manner are extremely high. It will be appreciated that during closing of a valve the cross-sectional area of flow decreases to zero. This decreasing of flow area causes a corresponding increase in flow velocity during closing of the valve, and therefore increases the local wear at the valve.
In a typical industrial CNC environment, cutting apparatus can be required to start and stop extremely frequently. This translates to frequent opening and closing of valves against pressurised abrasive flow, and rapid wear and deterioration of these valves. As a result, the use of ASJ systems for CNC machining is known to be inherently impractical.
ASJ systems have found use in on-site environments, such as oil-and-gas installations and sub-sea cutting, where the cutting required is largely continuous. ASJ systems have not been commercially used in industrial CNC machining.
FIGS. 2a and 2b show schematic representations of known ASJ systems. In a basic single stream system 30, as shown in FIG. 2a, a high pressure water pump 32 propels a floating piston 34. The piston 34 pressurises an abrasive slurry 36 and pumps it into a cutting nozzle 38.
A simple dual-stream system 40 is shown in FIG. 2b. Water from the pump 32 is divided into two streams, one of which is used to pressurise and pump a slurry 36 by means of a floating piston 34 in a similar manner to the single stream system 30. The other stream, a dedicated water stream 35, is combined with a pressurised slurry stream 37 at a junction prior to the cutting nozzle 38.
Both of these systems suffer from the problems outlined above, and result in very high valve wear rates. Other problems include an inconsistent cutting rate due to extreme wear in the tubes and nozzle.
In continuous flow systems, such as sub-sea applications, known ASJ systems are limited in that operating properties of the system such as the system pressure, and the ratio of water to abrasive slurry, must be set prior to operation, or even at the time of manufacture.
An alternative arrangement is proposed in U.S. Pat. No. 4,707,952 to Krasnoff. A schematic arrangement of the Krasnoff system 50 is shown in FIG. 3a. The Krasnoff system is similar to the dual-stream system 40, with the difference being that mixing of the water stream 35 and slurry stream 37 takes place in a mixing chamber 52 within the cutting nozzle 38.
A more detailed view of the mixing chamber 52 of Krasnoff is shown in FIG. 3b. The nozzle 38 provides a two-stage acceleration. Firstly, the water stream 35 and the slurry stream 37 are accelerated through independent nozzles leading into the mixing chamber 52. Then the combined water and abrasive stream is accelerated through the final outlet 54.
The Krasnoff system is arranged to operate at a pressure of about 16 MPa, significantly lower than other ASJ systems. As such, the impact of the slurry stream 37, whilst still damaging to valves, results in reduced valve wear rates than in higher pressure systems. The corollary is, of course, that the power output of the Krasnoff system is even lower than other ASJ systems, and thus its commercial applications are small. The applicant is not aware that the Krasnoff system has ever been commercially applied.
The present invention seeks to provide a system for creating a high pressure water jet with entrained abrasive particles which overcomes, at least in part, some of the above mentioned disadvantages of above AWJ and ASJ systems.
SUMMARY OF THE INVENTION
In essence, the present invention proposes a method which combines many of the advantages of AWJ and ASJ systems whilst reducing some of the disadvantages of each system.
In accordance with a first aspect of the present invention there is provided a high pressure cutting arrangement comprising a liquid stream and a slurry stream, the slurry comprising abrasive particles suspended in a liquid, energy being supplied to the liquid stream by a first energising means and energy being supplied to the slurry stream by a second energising means, each of the first and the second energising means being selectively operable, wherein the liquid stream and the slurry stream are combined to form an energised liquid and abrasive stream, at least a portion of the supplied energy being converted to kinetic energy in a cutting tool to produce a combined liquid and abrasive stream at high velocity. The use of separate energising means allows control over stream flows in the system.
The liquid stream and the slurry stream may be combined in the cutting tool. Alternatively, the liquid stream and the slurry stream may be combined ‘upstream’ of the cutting tool and supplied to the cutting tool under pressure.
Preferably the energy supplied by the first energising means is provided by a pump, most preferably a constant pressure pump, which pressurises the liquid stream. Similarly, the energy supplied by the second energising means is preferably provided by a pump, most preferably a constant flow pump. This arrangement allows the velocity and volume rate of the combined stream to be regulated by control of the pressure of the constant pressure pump, whilst the flow rate of abrasive material can be independently set by controlling the flow rate of the constant flow pump. Adjustment of the system power, or the fluid:abrasive ratio, can thus be readily achieved.
In a preferred embodiment, the constant flow pump energises a floating piston, which in turn pressurizes the slurry stream. In this embodiment a valve may be provided between the pump and the floating piston, such that the flow of liquid and therefore energy from the constant flow pump to the floating piston can be instantly prevented. Conveniently, this valve may also act to prevent back flow of liquid from the floating piston. In this way pressure and flow in the slurry stream can be allowed to vary whilst maintaining constant pressure in the liquid stream. The valve may simply act to divert the constant liquid flow away from the floating piston, for instance by returning the liquid to a reservoir of the pump.
In its preferred form the streams are allowed to combine in such a way that the pressure of the slurry stream is governed primarily by the pressure of the liquid stream. There may be a combining chamber into which the liquid stream, when energised, is provided at a constant pressure; and the slurry stream, when energised, is provided at a constant rate. The pressure at an entry region of the combining chamber is thus set by the pressure of the liquid stream. The point of entry of the slurry stream into the combining chamber is exposed to this pressure, in such a way that the slurry stream is prevented from entering the combining chamber unless the pressure in the slurry stream is marginally higher than the pressure at the combining chamber entry point. The action of the constant volume pump builds the pressure in the slurry stream until it reaches this point. A first equilibrium condition is then achieved where slurry is provided at a constant flow rate, and at the required pressure, into the combining chamber. Under these conditions the constant volume pump effectively acts as a constant displacement delivery pump.
When the second energising means ceases providing energy to the slurry stream, for instance by closing of the valve between pump and piston in the preferred embodiment, the pressure of the liquid stream in the combining chamber continues to act on the slurry stream. Slurry from the slurry stream continues to enter the combining chamber until such time as the pressure in the slurry stream drops marginally below the pressure in the combining chamber. At this point, the flow of slurry ceases but the pressure in the slurry stream is maintained. This enables a valve in the slurry stream to be closed against a static, albeit pressurised, abrasive stream. The valve is subject to a considerably reduced wear rate in comparison to one closing against a flowing abrasive stream. Closure of this valve ensures that the only flow to the cutting head is water. Subsequent closure of a valve in the water stream will prevent all flow of liquid through the cutting head.
Preferably the liquid stream, and hence the slurry stream, operate at a pressure of about 300 MPa.
It will be appreciated that the ceasing of energy supply from the second energising means results in an almost instantaneous ceasing of slurry, due to the small pressure difference in the slurry between a flowing state and a static state. Similarly, when the second energising means is activated, the required flow of slurry into the combining chamber is achieved almost instantaneously.
It will be appreciated that the slurry may represent between 3% and 30% of the combined flow (that is, with water representing between 97% and 70%) of the flow by weight. The present invention provides the ability to vary these proportions during operation by varying the operating speed and power of the respective pumps.



BRIEF DESCRIPTION OF THE DRAWINGS
It will be convenient to further describe the invention with reference to the accompanying drawings which illustrate preferred embodiments of the high pressure cutting arrangement of the present invention. Other embodiments are possible, and consequently, the particularity of the accompanying drawings is not to be understood as superseding the generality of the preceding description of the invention. In the drawings:
FIG. 1 is a schematic cross sectional view of a cutting tool of an AWJ system of the prior art;
FIG. 2a is a schematic view of a single fluid ASJ system of the prior art;
FIG. 2b is a schematic view of a dual fluid ASJ system of the prior art;
FIG. 3a is a schematic view of a dual fluid ASJ system of the prior art where fluids are injected into a cutting nozzle;
FIG. 3b is a cross sectional view of the prior art cutting nozzle of FIG. 3a; 
FIG. 4a is a schematic view of the high pressure cutting arrangement of the of the present invention using a single piston;
FIG. 4b is a schematic view of the high pressure cutting arrangement of the present invention using a second piston
FIG. 5 is a cutting tool from within the cutting arrangement of FIG. 4;
FIG. 6 is a cross sectional view of a portion of the cutting tool of FIG. 5, including a nozzle;
FIG. 7 is a cross sectional view of a focussing nozzle within the cutting tool of FIG. 5;
FIG. 8 is a cross sectional view of an alternative embodiment of a focussing nozzle for use within the cutting tool of FIG. 5; and
FIG. 9 is an alternative embodiment of a cutting tool for use within the cutting arrangement of FIG. 4.



DETAILED DESCRIPTION
FIGS. 4a and 4b show a schematic arrangement of a high pressure cutting system 100. The cutting system 100 has a cutting tool 110, to which is attached two input lines: a fluid or water flow stream 112 and a slurry flow stream 114. Each of the water flow stream 112 and the slurry flow stream 114 are supplied to the cutting tool 110 under pressure.
Pressure is applied to the water flow stream 112 by a first pump, being a constant pressure pump 116. In this embodiment, the constant pressure pump 116 is an intensifier type pump. The constant pressure pump 116 ensures that pressure in the water flow stream 112 is maintained at a constant, desired pressure. The desired pressure may be altered by control of the constant pressure pump 116. A typical available pressure range may be 150 MPa to 600 MPa. In typical operation, water pressure of about 300 MPa will provide a useful result.
Pressure is applied to the slurry flow stream 114 by a floating piston 118 which is powered by a second pump 120. In this embodiment, the constant flow water pump 120 is a multiplex pump. The floating piston 118 pushes a suspension of abrasive particles in water along the slurry flow stream 114, at a high density and low flow rate. The flow rate of the slurry stream 114 is governed by the flow rate of water 122 being pumped by the constant flow water pump 120. The desired flow rate of slurry may be altered by control of the constant flow pump 120. A typical flow rate of slurry is about one litre per minute.
In order to achieve a continuous supply of slurry, two floating pistons 118a and 118b may be employed as shown in FIG. 4b. In this embodiment slurry can be introduced into the vessel housing piston 118b while piston 118a is dispensing slurry into the flurry flow stream 114. When the vessel housing piston 118a is emptied of slurry, a valve can be switched to allow the dispensing of slurry from the vessel of piston 118b, while the first vessel is being replenished.
It will be appreciated that independent valves connect both vessels 118a and 118b to the slurry stream 114. These valves need only be operated when the pressure exerted by the relevant piston 118a, 118b matches the pressure in the slurry stream 114.
There is a valve 124 located along the water flow 122 between the constant flow pump 120 and the floating piston 118. Closure of the valve 124 redirects the water flow 122 away from the floating piston 118, and back to the constant flow pump 120. Closure of the valve 124 thus immediately ceases the supply of pressure to slurry stream 114. The valve 124 also prevents the backflow of water from the floating piston 118 to the constant flow pump 120, and thus hydraulically locks the floating piston 118, thereby also preventing the backflow of slurry from the slurry stream 114.
The cutting tool 110 includes a substantially cylindrical body portion 126 having a substantially cylindrical nozzle 128 extending from an outer end thereof. An inner end of the body portion 126 is connected to two injectors: an axial slurry injector 130 and an annular water injector 132. The injectors are arranged such that the water stream and the slurry stream both enter the body portion 126 in an axial direction, with the water stream being annularly positioned around the slurry stream. The water injector 132 includes flow straighteners to substantially remove turbulence from the water flow before entry into the body portion 126. In the embodiment of the drawings, water flow enters the water injector 132 in a radial direction and is then redirected axially. The flow straighteners, being a plurality of small tubes, assist in removing the turbulence created by this redirection.
The cutting tool 110 includes a slurry valve 131 located upstream of the slurry injector 130, and a water valve 133 located upstream of the water injector 132. The slurry valve 131 and the water valve 133 are each independently operable, and can be open or shut to permit or prevent flow.
An axial connection 135 between the slurry valve 131 and the slurry injector 130 is of variable length.
The nozzle 128 can be best seen in FIG. 6. The nozzle includes a combining chamber 134 and a focussing region 136. The combining chamber includes an entry region 138. The combining chamber 134 is also a conical accelerating chamber, with a cone angle of about 13.5 degree.
The focussing region 136 is a constant-diameter portion of the nozzle immediately adjacent a nozzle outlet 140. The focussing region has a length:diameter ratio of at least 5:1, and preferably greater than 10:1.
The entry region 138 is arranged to receive slurry flow through an axially aligned inlet tube 142 of substantially constant diameter. The entry region is also arranged to receive water through an axially aligned annulus 144 about the inlet tube 142. The annulus 144 has an outer diameter about three to four times the diameter of the inlet tube 142. The annulus 144 joins the inner wall of the combining chamber 134 in a continuous fashion, thus reducing any propensity for the introduction of turbulence into the water flow.
The position of the entry tube 142, and hence the entry region 138, is variable. The position can be varied by adjustment of the axial connection 135. The axial positioning of the entry region 138 allows for the water flowing through the annulus 144 to be accelerated to a desired velocity before it enters the entry region 138. This allows for the calibration of the flows of water and slurry, and may allow an operator to adjust for wear or loss of power.
In the embodiment of the drawings the focussing region 136 is formed within a separate focussing nozzle 146 which is axially connected to the combining chamber 134. The focussing nozzle 146, as shown in FIG. 7, includes an accelerating region 148 immediately prior to the focussing region 136. The accelerating region 148 has a cone angle greater than or equal to that of the combining chamber 134. The accelerating region 148 has a diameter at inlet substantially identical to the diameter at an outlet of the combining chamber 134. It is considered desirable that the inlet diameter of the accelerating region 148 be not significantly greater than the outlet diameter of the combining chamber 134 in order to reduce any propensity for the introduction of turbulence.
The focussing nozzle 146 may be formed of a harder, more abrasive resistant material than that of the combining chamber 134. As such, the respective portions of the nozzle 128 may be designed such that the fluid/abrasive stream is accelerated to a first velocity, for instance 250 msec, in the combining chamber, and then accelerated to its final velocity in the accelerating region 148. The respective velocities can be designed and selected in accordance with the abrasive resistance of the materials used in the two portions.
In an alternative embodiment, as shown in FIG. 8, the focussing nozzle 146 is a compound nozzle, with the accelerating region 148 formed from a particularly hard, abrasive resistant material such as diamond and the focussing region 136 formed from another suitable material such as a ceramic material. In this embodiment the diameter of the focussing region 136 is designed to be equal to or slightly smaller than the minimum (exit) diameter of the accelerating region 148.
In both embodiments the nozzle 128 is of sufficient length to allow the required velocity of a water/slurry mix to be met, typically up to 600 m/sec. It will be noted that, in the embodiment of the drawings, this requires the diameter of the focussing region 136 to be less than that of the slurry inlet tube 142.
The nozzle includes a chamfered exit 150 at the outlet 140. The cone angle of the chamfer is sufficient to ensure separation of flow at the exit 150. In the embodiment of the drawings, this angle is 45 degrees.
In a further alternative embodiment, as shown in FIG. 9, the focussing nozzle 146 is contained within an external holder 152. The chamfered exit 150 in this embodiment is formed within the external holder 152.
In use, water is pressurised to the required pressure by the constant pressure pump 116. It is pumped under this pressure to the cutting tool 110, through the annular water injector 132, and then into the annulus 144. From the annulus it enters the entry region 138, and establishes a pressure in the entry region 138 close to the pressure at which it was pumped.
Slurry, energised by the floating piston 118, is pumped along to the cutting tool 110, through the slurry injector 130 into the inlet tube 142.
It will be appreciated that slurry will only proceed into the entry region 138 when pressure in the inlet tube 142 exceeds the pressure in the entry region 138. When slurry is flowing, the action of the floating piston 118 (powered by the constant flow pump 120) acts to increase pressure in the slurry flow stream until it is sufficiently high to enter the entry region 138 of the combining chamber 134. It will be appreciated that this is marginally higher than the pressure created in the entry region 138 by the water flow. When this pressure is established in the slurry stream, the action of the pump 120 will result in slurry being continuously supplied to the chamber 134 at a constant rate and pressure.
Water and slurry will be rapidly advanced and mixed along the chamber 134. The annular water flow will largely protect the walls of the chamber 134 from the abrasive action of the slurry, at least at the inner part of the nozzle 128.
By the time the flow has been accelerated to the focussing nozzle 146, the water and slurry will be well mixed. At least an entry portion of the focussing nozzle must therefore be constructed from an abrasion-resistant material, such as diamond.
The flow will exit the focussing nozzle 146 through the outlet 140 at an extremely high velocity, suitable for cutting many metals and other materials.
When cutting is to be stopped, the valve 124 is activated to immediately cease operation of the floating piston 118. It will be appreciate that the valve 124 is only acting against water, not abrasive material, and therefore is not subject to extreme wear.
The ceasing of the floating piston 118 will cause energy to stop being added to the slurry stream 114. This will result in pressure dropping in the slurry stream 114 and the inlet tube 142.
As soon as pressure in the inlet tube 142 drops marginally below the water pressure in the entry region 138, the water pressure will prevent the flow of slurry into the entry region 138. It will be appreciated that this occurs virtually instantaneously on activation of the valve 124. The output jet will change from being a water/slurry jet to being a water only jet.
At this point the slurry stream 114 will be maintained under high pressure, zero velocity conditions. In these conditions the slurry valve 131 can be closed without subjecting the valve 131 to excessive wear.
Once the slurry valve 131 has been closed, the water valve 133 can be closed in order to cease the flow of water. This sequence of valve closures can be controlled rapidly, thus providing a convenient means to start and stop cutting at the cutting tool 110.
When cutting is to be recommenced, the valve control sequence can be implemented in reverse, with water valve 133 being opened first, followed by slurry valve 131. Subsequent opening of the valve 124 will result in a virtually instantaneous reestablishment of the slurry flow into the combining chamber 134.
Control over the cutting properties of the exit flow can be achieved through several measures, including changing the operating pressure of the constant pressure pump 116, changing the volume supplied by the constant volume pump 120, and changing the density of the slurry supplied to the system.
Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention.

## Claims

1. A high pressure cutting arrangement comprising a liquid stream and a slurry stream, the slurry comprising abrasive particles suspended in a liquid, energy being supplied to the liquid stream by a first energising means and energy being supplied to the slurry stream by a second energising means, each of the first and the second energising means being selectively operable, wherein the liquid stream and the slurry stream are combined to form an energized liquid and abrasive stream, at least a portion of the supplied energy being converted to kinetic energy in a cutting tool to produce a combined liquid and abrasive stream at high velocity.

2. A high pressure cutting arrangement as claimed in claim 1, wherein the energy supplied by the first energising means is provided by a constant pressure pump.

3. A high pressure cutting arrangement as claimed in claim 2, wherein the energy supplied by the second energising means is provided by a constant flow pump.

4. A high pressure cutting arrangement comprising a liquid stream and a slurry stream, the slurry comprising abrasive particles suspended in a liquid, energy being supplied to the liquid stream by a first pump and energy being supplied to the slurry stream by a second pump, each of the first and the second pumps being selectively operable, wherein the liquid stream and the slurry stream are combined to form an energised liquid and abrasive stream, at least a portion of the supplied energy being converted to kinetic energy in a cutting tool to produce a combined liquid and abrasive stream at high velocity.

5. A high pressure cutting arrangement as claimed in claim 4, wherein the second pump energises a piston, which is turn pressurises the slurry stream.

6. A high pressure cutting arrangement as claimed in claim 5, wherein a valve is provided between the second pump and the piston in order to selectively prevent the flow of energy from the pump to the piston.

7. A high pressure cutting arrangement as claimed 5, wherein the second pump alternately energises each of two pistons, which in turn pressurise the slurry stream.

8. A high pressure cutting tool as claimed in claim 4, wherein the pressure in the liquid stream and in the slurry stream is about 300 MPa.

9. A method for operating a high pressure cutting arrangement as claimed in claim 4, the method comprising:
supplying energy to the liquid stream by the first pump;
supplying energy to the slurry stream by the second pump;
combining the liquid stream and the slurry stream to form the energised liquid and the abrasive stream, at least a portion of the supplied energy being converted to kinetic energy in the cutting tool to produce the combined liquid and abrasive stream at high velocity.

10. The method of claim 9, wherein the first pump and the second pump are independently operated to independently respectively control the liquid stream and the slurry stream.

11. The high pressure cutting arrangement as claimed in claim 4, wherein the first and the second pumps are independently selectively operable to independently respectively control the liquid stream and the slurry stream.