In water-jet cutting industry, working pressures of 3 to 4 kbar are currently state-of-the art. In most applications at these pressures, abrasive particles are mixed into the water jet in order to maximise the cutting energy and hence the working speed. If the pressure is increased beyond 4 kbar, even higher cutting speeds can be realised or - if desired - the use of abrasive particles can be avoided. This paper discusses the reliability of the mechanical component that causes most of the maintenance cost of a water-jet cutting system: the pressure intensifier. Parts that exhibit excessive wear at increased pressures are analysed. Design concepts and practical solutions for reliable cutting at 4 to 7 kbar are presented.
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