Patent Application
20150202740
The present invention relates to an orifice for a high-pressure waterjet cutter. More specifically, the present invention relates to a diamond orifice for a high-pressure waterjet cutter.
High-pressure waterjet cutters are known, as are orifices for high-pressure waterjet cutters. High-pressure waterjet cutters typically include a housing, such as a tube, that directs pressurized water to an orifice. The orifice constricts the flow of pressurized water from the housing into a focused stream, and directs the focused stream through a further housing and bore and out of the waterjet cutter.
Some high-pressure waterjet cutters also include an inlet, disposed downstream of the orifice, that draws abrasive particles into the focused stream of water prior to the stream of water exiting the waterjet cutter. The abrasive particles facilitate and add to the cutting power of the focused stream of water exiting the waterjet cutter.
In one construction, the invention provides an orifice for a high-pressure waterjet cutter including a first surface defining an inlet plane, a second surface defining an outlet plane, and an inner bore aligned along a flow axis and extending from the first surface to the second surface. The orifice also includes a first layer of polycrystalline diamond extending from the first surface to a plane between the inlet plane and the outlet plane, and a second, separate layer of polycrystalline diamond extending from the plane to the second surface. The first layer and the second layer are coupled to one another to define a single component. The second layer has material properties different than the first layer.
In another construction, the invention provides an orifice for a high-pressure waterjet cutter including a first surface defining an inlet plane, a second surface defining an outlet plane, and an inner bore aligned along a flow axis and extending from the first surface to the second surface. The orifice also includes a first layer of material extending from the first surface to a plane between the inlet plane and the outlet plane, and a second layer of material extending from the plane to the second surface. The first layer and the second layer are coupled to one another to define a single component. The first layer provides superior impact resistance when compared to the second layer. The second layer provides superior cavitation resistance when compared to the first layer. The second layer provides superior wear resistance when compared to the first layer.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
Before proceeding, it should be noted that the term “high pressure” as used herein refers to pressure levels in excess of about 15,000 psi with systems operating at pressure levels over 100,000 psi possible. The extreme pressure levels used in water jet cutters makes the application of common low pressure components impossible or difficult.
As illustrated in
As illustrated in
The orifice assembly 18 further includes an orifice holder 58 and an orifice 62 both disposed within the cavity 38. The orifice holder 58 retains and holds the orifice 62 inside of the cavity 38. The orifice holder 58 includes an inner bore 66 that extends through a top portion 70 of the orifice holder 58 and is sized and configured to permit passage of water from above the orifice holder 58 to the orifice 62. The inner bore 66 is aligned along the flow axis 54.
With reference to
With continued reference to
The orifice 62 includes a second, separate layer 122 of pseudo-monocrystalline diamond extending from the first plane 114 to a second plane 126 between the first plane 114 and the outlet plane 86. The second, pseudo-monocrystalline layer 122 may be a true monocrystalline layer, or may be a polycrystalline layer having a uniform make-up such that the layer has material properties similar to the material properties of a true monocyrstalline layer or material properties that at least closely resemble that of a monocrystalline layer. The second plane 126 is disposed at a transition between the cylindrical portion 94 and the frustoconical portion 98, but could be positioned at other locations. The second layer 122 may include a plurality of sublayers 130 permanently bonded to one another or may be a single layer. In some constructions each sublayer 130 includes substantially the same material.
The orifice 62 includes a third, separate layer 134 of polycrystalline diamond extending from the second plane 126 to the second surface 82. The third layer 134 may include a plurality of sublayers 138 permanently bonded to one another or may be a single layer. In some constructions each sublayer 138 includes substantially the same material.
The first layer 110, the second layer 122, and the third layer 134 are permanently bonded to one another to define an inseparable single component. In some constructions the first layer 110, the second layer 122, and the third layer 134 are coupled to one another to form a single component but are not permanently bonded to one another. In some constructions the first layer 110 and the third layer 134 are made of the same material. In some constructions one or more of the first layer 110, the second layer 122, and the third layer 134 do not include any binders, as binders may sometime cause problems with cavitation.
In the illustrated construction the first layer 110 of polycrystalline diamond provides superior impact resistance when compared to the second layer 122 of pseudo-monocrystalline diamond. In some constructions the first layer 110 of polycrystalline diamond also provides superior impact resistance when compared to the third layer 134 of polycrystalline diamond. In the illustrated construction the second layer 122 of pseudo-monocrystalline diamond provides superior cavitation resistance when compared to the first layer 110 of polycrystalline diamond and the third layer 134 of polycrystalline diamond. In the illustrated construction the third layer 134 of polycrystalline diamond provides superior wear resistance when compared to the second layer 122 of pseudo-monocrystalline diamond. In some construction the third layer 134 of polycrystalline diamond also provides superior wear resistance when compared to the first layer 110 of polycrystalline diamond.
The first layer 310 extends from a first surface 274 to a plane 314 disposed at a transition between a frustoconical portion 306 and a cylindrical portion 294. The first layer 310 may include a plurality of sublayers 318 or may be formed from a single sublayer of material. In some constructions each sublayer 318 includes substantially the same material having the same material properties. In some constructions the sublayers 318 are permanently bonded to one another.
The second layer 334 extends from the plane 314 to a second surface 282. The second layer 334 may include a plurality of sublayers 338. In some constructions each sublayer 338 includes substantially the same material having the same material properties. In some constructions the sublayers 338 are permanently bonded to one another.
In one arrangement, the first layer 310 provides superior impact resistance when compared to the second layer 334. The second layer 334 provides superior cavitation resistance when compared to the first layer 310. The second layer 334 provides superior wear resistance when compared to the first layer 310.
In some constructions one or more physical properties of each sublayer is varied slightly to provide different material properties and a uniform transition between those material properties. For example, one construction may vary a particle size within each sublayer 318 and 338, thus providing a continuous change in material properties moving from the first surface 274 to the second surface 282.
The orifices 62, 162, 262, and 362 include various materials that provide desired material properties at different points within the orifices. The orifices include specific desired material properties at desired points of the orifices, unlike prior orifices manufactured from a single homogeneous material.
While four arrangements of an orifice are illustrated herein, the invention should not be limited to these four arrangements alone. For example, constructions with different bore arrangements or layer arrangements (e.g., more or fewer) are contemplated. In some constructions, the polycrystalline layers slowly transition to different arrangements axially along the bore. For example, a binder may be cobalt in a first sublayer of a polycrystalline layer and could slowly transition to a completely different binder at the last sublayer with sublayers therebetween being a combination of the two binders. In yet another arrangement, the layers are arranged circumferentially around the bore rather than axially along the bore. As one of ordinary skill in the art will realize, many arrangements of the multiple layers are possible.
The term “superior impact resistance” as used herein refers to an impact resistance (e.g., a fracture toughness as measured for example in Mpa) that is about 50% better, and preferably 2-3 times better, than a comparative impact resistance of another layer. The term “superior cavitation resistance” as used herein refers to cavitation resistance that is greater than a comparative cavitation resistance of another layer. For example, the illustrated second layer 122 of pseudo-monocrystalline diamond in
Various features and advantages of the invention are set forth in the following claims.
