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Waterjet Rises to the Challenge

5-axis waterjet cutting—exactly what GNB Corp. needed for net part shapes with weld preparations already included.

GNB Corporation has a proven track record of manufacturing high quality, reliable products since 1968. They are known primarily as a manufacturer of large vacuum valves; however the company offers a diverse range of products and services, such as machining, welding and assembly of custom metal tanks and fabricated structures. The company is ISO 9001:2008 with Design certified. Additionally, they have standard product lines consisting of vacuum gate valves, angle & pendulum valves, vacuum chambers, and custom flanges and fittings.

GNB was started over 40 years ago by an engineer named Gary N. Burnett, who started the company in his garage making small items such as heat shields. Eventually Gary generated enough business to move his manufacturing to a building where he took almost any type of work he could find. In the 70’s and 80’s, Burnett worked to simplify his vacuum valve designs and much of his engineering and design work can still be seen in the company’s current gate valve designs. Since then, the company has dramatically increased their capacity by adding three large CNC mills, two smaller mills, a large CNC 5-axis waterjet, several leak test stations and many weld stations.

Located in Elk Grove, CA, the 50,000 sf facility’s full complement of fabrication, welding, assembly, and test equipment assures the highest product quality and reliability. GNB realized they faced a situation where weld preparation and set-up times were higher than actual welding times. They decided they would benefit by adding waterjet cutting capabilities to their fabrication services. They were primarily cutting 6' x 12' x ½" thick stainless steel (up to 5" thick) and needed a method of cutting material with the beveled weld preps directly onto the net shapes of the parts. Their goal was to eliminate all machining, beveling and grinding during the weld preparation process.

Waterjet Solution

Kirk Carter, Director of Supply Chain Management, flew from California to Ohio to have a plant tour at WARDJet's manufacturing facility. He had very specific ideas that GNB needed to see go from drawing to product. WARDJet demonstrated how those parts could be cut from start to finish using the new X-Series Controller. This allowed 5-axis cutting, precisely what GNB needed for net part shapes with weld preparations already included.

While other waterjet manufacturers claimed to have an economical 5-axis solution, after the tests were performed, WARDJet was determined to be the best value for the money. GNB purchased a WARDJet ZX-813 waterjet with a WARDJet X-Series Controller, 100 hp pump & a 5-Axis waterjet cutting head. A GNB technician and engineer attended training at WARDJet's facility and more training was given again on-site with the installation of the system.

Angle Valve Project

One of the unique manufacturing challenges was presented by GNB’s angle (or poppet) valve product line. The body of an angle valve is constructed of two cylindrical tubes that intersect one another at a right angle. In the past, GNB made this body by coping the tubes by hand using a printed paper template. This was an expensive and time consuming process

GNB's goal was to manufacture the body of their Angle Valves by waterjet cutting the flat plate with all penetrations prior to rolling. Many said this could not be done, and it did prove to be initially difficult. Not only are there penetrations for ports, there is a large branch port which requires perfect match up. Rising to the challenge, and, after several attempts, GNB now accomplishes this task quickly and with exacting precision.

The knowledge garnered from the Angle Valve Project has spawned many other benefits that the 5-axis cutting head has provided. GNB has virtually eliminated the grinding of weld preparations. This experience now applies to all GNB’s products as they constantly look for ways to save time and provide the highest quality products to their customers.

Benefits

By now, just about everyone in manufacturing understands the benefits of waterjet cutting. By far the most important benefit of the waterjet cutter is the ability to cut material without interfering with the material’s inherent structure as there is no heat-affected zone. Minimizing the effects of heat allows metals to be cut without harming or changing intrinsic properties. In addition, waterjet cutting is considered a “green” technology. Waterjets produce no hazardous waste and the garnet abrasive is a non-toxic natural substance that can be recycled for repeated use. Waterjets also eliminate airborne dust particles and contaminates which greatly improves the work environment and reduces problems arising from operator exposure.

By investing in a WARDJet 5-axis waterjet, GNB has cut their production costs and has increased material utilization rates. When discussing the benefits of waterjet cutting Kirk Carter commented, “In this competitive business environment, GNB could not afford to be without its 5-axis waterjet. We are focused on providing the best value for our customers and the WARDJet machine gives us a competitive advantage.”

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