EFFECTIVE AND SUSTAINABLE WATER JET CUTTING

Enclosure 1 – Project Plan, Broman, BTH

EFFECTIVE AND SUSTAINABLE WATER JET CUTTING

- an integrated multidisciplinary study

Industrial Challenge
Water jet cutting has a great potential of being an effective and sustainable manufacturing
technology. Some advantages are clean cut edges, high accuracy and flexibility, low material
loss, inert and abundant main processing substances (water, sand) and negligible thermal
influence on the work piece.
Water Jet Sweden (WJS) provides development, manufacture, sales, education and
maintenance of customized, complete water jet cutting systems. Customers include, e.g., aircraft,
aerospace, automotive and machine manufacturing industries. GE Fanuc Automation (FA)
provides development, manufacture, sales, education and maintenance of customized control
systems for manufacturing machines, in particular for water jet cutting.
A reason for the success of the water jet cutting machines, consisting of the present products
of these companies, is the particularly high cutting accuracy, achieved by innovative design and
own patents. However, a strong demand for increased cutting speed has developed. There is also
increasing environmental awareness among customers and authorities. The next generation of
machines therefore needs to combine increased cutting speed with maintained or improved
cutting accuracy and environmental/sustainability performance. This complex task calls for
research-based development and use of modern support methods for virtual prototyping 1 and
sustainability assessment 2 . WJS and FA have therefore joined forces with each other and with
Blekinge Institute of Technology (BTH) to address this challenge.

Scientific Challenge, Methodology and Expected Results

To deal with the industrial challenge it is necessary to take a multidisciplinary approach that
involves fluid dynamics, machine dynamics/virtual prototyping and sustainability assessment as
the main and interrelated areas.

Fluid Dynamics
We will investigate some preliminary ideas for obtaining improved cutting performance.
Polymeric additive is one promising approach. Experimental investigations have shown that
nozzle friction can be reduced and jet stability improved 3 . The additives change the rheology of
the cutting liquid and decrease the jet divergence by increased cohesion forces. The basic
mechanisms behind the experimental results are, however, not yet fully understood.
In fact, there is an incomplete theoretical understanding at an even more fundamental level. A
liquid jet in a liquid as well as a gas jet in a gas, having, e.g., marine and aerospace applications,
have been comprehensively studied 4 . However, for a liquid jet in a gas, as in the water jet cutting
application, fewer fundamental results seem to be available in the literature 5 .
We will therefore first try to establish a better theoretical understanding of this latter case,
starting with only water as the liquid. We will successively add complexity by including

1
Prediction, description and assessment of technical product characteristics without a full physical prototype.
2
Assessment of materials, products and services through a lens of basic principles for sustainability, to be considered
already at product development.
3
See, e.g., Louis H., Pude F. and von Rad Ch., Potential of Polymeric Additives for the Cutting Efficiency of Abrasive
Waterjets, Proceedings of the American Waterjet Conference, Houston, Texas, USA, August 17-19, 2003.
4
For reviews, see, e.g., Journal of Fluid Mechanics, Special Issue May 1981, Cambridge University Press, 1981;
Landau L.D. and Lifshits E.M., Hydrodynamics, Academic Press, NY, 1986; Landa P.S. and McClintok P.V.E.,
Development of Turbulence in Subsonic Submerged Jet (Submitted for publication by Elsevier).
5
See, e.g., Schlichting H. and Gersten K., Boundary Layer Theory, 8th Revised and Enlarged Edition, Springer, 2000;
Liu H., Wang J., Brown R.J. and Kelsson N., Computational Fluid Dynamics Simulation of Ultrahigh Velocity
Abrasive Waterjet, Key Engineering Materials, Vols. 233-236, 2003.
EFFECTIVE AND SUSTAINABLE WATER JET CUTTING
Enclosure 1 – Project Plan, Broman, BTH

polymeric additives and abrasive particles. We will also investigate some other ideas of cutting
liquid manipulation; the gas content and purity of the cutting liquid are, e.g., important factors.
We believe that a thorough theoretical understanding is a prerequisite for a breakthrough in
cutting performance. The present (empirical) nozzle design has been the same for more than
thirty years worldwide. This probably implies a great potential for improvement. Theoretical
modeling and simulation will support optimization of, e.g., nozzle design and additive
concentration for various operation conditions. Surely the optimal nozzle design will be different
for (water) and (water/additive), respectively.
This work will involve fluid dynamics, solid mechanics, thermodynamics, tribology and
optimization as the main topics. Cutting tests will be performed for verification and modeling
support. We expect to reach design guidelines regarding the above ideas for improved cutting
performance. Innovative ideas and patents are possible outcomes. We expect publications that
will bring state-of-the-art further in this area.

Machine Dynamics/Virtual Prototyping

Improved jet performance bears the potential of improved productivity (increased cutting speed).
On the other hand, higher velocities and accelerations of the nozzle heads and other machine parts
imply stronger excitation of oscillation. This makes it more difficult to follow a desired cutting
path, which is, of course, inherently negative for the accuracy.
We will investigate some preliminary ideas of design improvements for maintained or
improved cutting accuracy at increased cutting speed. Those relate to the mechanical design as
well as to the control system. The control system may compensate for mechanical flexibility if the
machine dynamics could be properly and rapidly predicted and the control system could be
properly designed and programmed for this purpose.
A thorough understanding of the interrelated machine- and control system dynamics is a
prerequisite for the above. To be able to perform optimization (repeated simulation), real time
dynamics prediction and virtual reality visualization, we need to develop modeling and
simulation procedures that are as computationally inexpensive as possible while still being
accurate enough for the characteristics they are supposed to describe. Our experience of such
“lean modeling and simulation” for other systems will be utilized 6 .
We will develop a virtual machine concept 7 that can also be used by the design engineers for
cost-effective optimization during future product development. The virtual machine will facilitate
testing of a large number of design configurations at an early stage and the total design that
maximizes productivity for a given accuracy could then be searched for. The virtual machine will
also facilitate, e.g., safety evaluation, early education of operators and marketing. Building,
testing and adjusting full physical prototypes for the above purposes is very costly and
impractical.
This work will involve multi-body and structural dynamics, control theory, mechatronics,
optimization and virtual reality as the main topics. We will repeatedly compare “virtual behavior”
with measured behavior for validation and modeling support. We expect to reach guidelines for

6
See, e.g., Broman G., Jönsson A, and Hermann M., Determining Dynamic Characteristics of Bellows by Manipulated
Beam Finite Elements of Commercial Software, International Journal of Pressure Vessels and Piping, ISSN 0308-
0161, Vol. 77, Issue 8, 2000; Wall J., Dynamics Study of an Automobile Exhaust System, Blekinge Institute of
Technology, Licentiate Dissertation Series No. 2003:08, 2003; Calleecharan Y. and Ahlin K., Fast Simulation of Non-
Linear Mechanical Systems, Proceedings of the International Modal Analysis Conference, Detroit, USA, January,
2004.
7
For introductory work, see, e.g., Jönsson, A., Bathelt, J. and Broman, G., Interacting With Real Time Simulations –
Virtual Reality in Industry Applications, Immersive Projection Technology and Virtual Environments 2003, Zurich,
Switzerland, May 22-23, 2003; Bathelt, J. and Jönsson, A., How to Implement the Virtual Machine Concept Using xPC
Target, Nordic Matlab Conference 2003, Copenhagen, Denmark, November 21-22, 2003.
EFFECTIVE AND SUSTAINABLE WATER JET CUTTING
Enclosure 1 – Project Plan, Broman, BTH

improved total design. Innovative ideas and patents are possible outcomes. We expect
publications that will bring state-of-the-art further in this area.

Sustainability Assessment
We will carry out a structured overall scanning 8 of the water jet cutting technology, based on a
methodology called “Backcasting from basic principles for sustainability”, previously published
and applied as The Natural Step (TNS) framework. This framework is underpinned by the basic
principles that underlay all kinds of known non-sustainable trends and impacts and that are not
constrained by any single region, impact or science area. These principles are derived from an
overarching systems perspective of the biosphere with its human societies 9 .
Starting from a “bird’s eye” perspective that covers the full concept of sustainability over the
lifecycle of studied materials, products or services, “hot-spot” issues that need further
investigation may be discovered, and detailed investigations of issues of minor significance may
be avoided, all resulting in improved efficiency and reduced risks from a producer’s
responsibility perspective.
A “hot-spot” issue that we already anticipate, and will make a thorough investigation of, is
that polymeric additives, fragments of the work piece material and the abrasive material
contaminate the water. From a sustainability point of view it is critical what types of additives
that are chosen and how the cutting liquid is handled after use depending on what materials that
are cut and what abrasive materials that are used.
The scanning will cover not only the water jet cutting technology as such, but also its
possibilities of contributing to a sustainable society-at-large. This may lead to the discovery of
new business opportunities as well as new ways of communicating in existing markets. We will
investigate the possibility of developing criteria for environmental labeling of water jet cutting
machines. The Nordic Swan environmental labeling board invites suggestions of such criteria for
new product categories 10 . Being at the leading edge of this development should be a clear
competitive advantage.
This work will involve environmental management systems, strategic life cycle assessment,
casual loop dynamics, multi-criteria decision support, physical resource theory, economy,
ecology and eco-toxicology as the main topics. We expect to reach concrete guidelines for
improved sustainability performance of water jet cutting machines as well as improved general
know-how of sustainable product development. Criteria for environmental labeling are possible
outcomes. We expect publications that will bring state-of-the-art further in this area.

Interrelation
As indicated there is possible interrelation between the above areas in several ways, which
motivates an integrated study. A few examples are:
- Improved jet dynamics allows for increased cutting speed. This influences machine
dynamics, which could be a concern for the cutting accuracy.
- Oscillation of the nozzle heads induces disturbances of the jet, which could be a concern for
the jet stability and thus for the possible cutting speed.
- The jet thrust force may influence machine dynamics, especially at turning on and shutting
off the jet, which could be a concern for the cutting accuracy.
8
This type of scanning has been done for, e.g., TV’s, refrigerators and recycling plants with Matsushita in Japan (who
subsequently won the Japanese Government’s award for best sustainability report).
9
See, e.g., Broman G., Holmberg J. and Robèrt K-H., Simplicity without Reduction: Thinking Upstream towards the
Sustainable Society, International Journal of the Institute of Management Sciences and the Operational Research
Society of America, Vol. 30, No. 3, 2000; Robèrt K-H., Schmidt-Bleek B., Aloisi de Larderel J., Basile G., Jansen J. L.,
Kuehr R., Price Thomas P., Suzuki M., Hawken P. and Wackernagel M., Strategic sustainable development – selection,
design and synergies of applied tools, Journal of Cleaner Production, No. 10, 2002.
10
Miljöeko, No. 6, 2003.
EFFECTIVE AND SUSTAINABLE WATER JET CUTTING
Enclosure 1 – Project Plan, Broman, BTH

- Improved productivity implies a potential for resource savings, which is beneficial from a
sustainability perspective.
- Polymeric additives may improve the cutting performance but it is critical from a
sustainability point of view what type of additives that are used.

Competence and Equipment

The researchers, their percentage of full-time assigned for the proposed project and their main
areas of activity are listed in table 1. These members have top level competences covering an
exceptionally wide field of science and extensive experience of relevance to this project. For
example; Kjell Ahlin has more than 30 years of experience in structural dynamics and
experimental mechanics and is active within the ISO, co-workers Göran Broman and Karl-Henrik
Robèrt have pioneered the development of the TNS framework, which uniquely covers the full
sustainability perspective and that has proven very powerful in guiding sustainability initiatives in
business and society worldwide 11 . Oleg Rudenko has authored 300 publications in theoretical
physics and is a member of the Russian Academy of Sciences. The background of the PhD-
students (mechanical, chemical and environmental engineering) also aligns well with this project.
Refer to enclosure 3 for more information. This group is part of a larger group in mechanical
engineering. There is also other supplementary competence at BTH, e.g., signal processing (Prof.
I. Claesson), environmental consequence assessment (Prof. L. Emmelin) and mathematics (Prof.
N. Ibragimov).

Table 1. Research group members and their activity.

Name Title % F M S
Kjell Ahlin Prof. 10 X
Göran Broman Prof. 50 X X X
Karl-Henrik Robèrt Prof. 10 X
Oleg Rudenko Prof. 25 X
Thomas Englund Lic. 20 X
Anders Jönsson Lic. 50 X
Johan Wall Lic. 80 X
Henrik Ny M.Sc. 40 X
(F = Fluid Dynamics, M = Machine Dynamics/Virtual Prototyping, S = Sustainability Assessment)

Examples of external partners of interest for this project are:

- Chalmers Water Jet Lab (Dr. Christian Öjmertz) is leading in experimental water jet research
and will perform some of the cutting tests of this project. Furthermore, Dr. Öjmertz is
president of the Swedish Water Jet Association, in which BTH is a member.
- Moscow State University is leading in theoretical jet dynamics. Prof. Rudenko is heading a
department within the faculty of physics (half time basis). Through this channel and the
Russian Academy of Sciences, we have access to supplementary top competence in fluid
dynamics.
- The Division of Computer Aided Design at Luleå University of Technology is leading in
machine dynamics and virtual prototyping. Assoc. Prof. Mikael Jonsson is a co-supervisor of
PhD-student Anders Jönsson.
- The Center for Product Development at the Swiss Federal Institute of Technology (Dr. Stefan
Dierssen and Prof. Marcus Meier) is leading in product development and virtual prototyping.

11
Prof. Robèrt was, e.g., rewarded The Blue Planet Prize (“Environmental Nobel”) for this work in 2000.
EFFECTIVE AND SUSTAINABLE WATER JET CUTTING
Enclosure 1 – Project Plan, Broman, BTH

We run similar virtual machine projects and mutually take part in each others work. Prof.
Andreas Kunz from this center has applied for an adjunct professorship at BTH.
- The Center for Environmental Studies at Lund University is leading in environmental
systems analyses. Assoc. Prof. Mats Svensson is a co-supervisor of PhD-student Henrik Ny.
Through this channel we also have access to supplementary top competence in environmental
chemistry, ecology and eco-toxicology.
- The Natural Step Foundation. Prof. Robèrt is at part time heading this international NGO.
Through this channel we have access to a worldwide network of other universities,
companies and municipalities at the leading edge of sustainable development.

WJS and FA have deep knowledge and experience of their products. In the project, CEO Jan Ryd
and R&D-manager Tony Ryd are the main individuals responsible on behalf of WJS. CEO Göran
Jönsson and CNC Engineer Hervé Currat are the main individuals responsible on behalf of FA.
Also other persons in the companies’ design groups will participate in, e.g., surveys, simulation,
experimental work, workshops, seminars and implementation.
BTH holds comprehensive and powerful equipment and software for computation and
measurement of mechanical characteristics of structures, 3D-modeling and virtual reality, rapid
prototyping, etc. Additional resources are available through partners in academia and industry.
For this project WJS and FA will provide a typical water jet cutting machine and control systems
for the experimental studies.

Related Research and Future Plans

The proposed project fits perfectly for the development of the mechanical engineering research
group. We strive to be a multidisciplinary group that in a few years will qualify for a profile
funding on efficient and sustainable product development from the KK-Foundation. We have
conducted several projects within our focus together with companies. With WJS, we recently
concluded a two-year KK-financed project, from which we have an embryo virtual machine (that
consists of a real control, bi-directionally connected to a simple machine simulation, which is
connected to a 3D-visualisation). With the proposed project we will considerably expand and
refine the modeling and simulation of the structural parts and the control system interaction, add
the other science areas and perform total design optimization (see previous description). We are
currently conducting such integrated work in a minor pre-study, financed by an EU-arena, to
prepare for the proposed project, which in turn will be a reference for the planned KK-profile. We
have included GE Fanuc Automation in the cooperation to strengthen our competence in systems
control engineering. Besides the expected results described above we also expect this project to
generate new interesting research questions for the coming profile.

Time Table
Parallel to the work in the three main areas (J, M, S) we will continuously study interrelation
between them as described above, which may alter our activities. We will also have other
common activities (C). Besides the continuous work related contacts and meetings we will have
two formal workshops a year where the project work is summarized and evaluated and results
transferred. These workshops will include a wider range of persons from the companies. The
companies could also invite suppliers, costumers and others if desired. We will also have three
large seminars open for other companies, branch organizations and others during the project. We
will continuously update a project web page and, of course, we will do formal reporting and
scientific publication through relevant journals and conferences.

The main steps of the project are summarized in table 2 and preliminary scheduled in figure 1.
 EFFECTIVE AND SUSTAINABLE WATER JET CUTTING
Enclosure 1 – Project Plan, Broman, BTH

Table 2. Main steps of the project.

F1 Literature studies. Analytical, numerical and experimental fluid dynamics studies
for basic understanding of water jet in air and influencing factors.
F2 Optimization/redesign to improve cutting performance with water. Tests.
F3 F1 and F2 with water + additive and other manipulation.
F4 F1 and F2 with water + abrasives.
F5 F1 and F2 with water + abrasives + additive and other manipulation.

M1 Literature studies. Multi-body and structural dynamics studies for expansion and
refinement of modeling and simulation of mechanical flexibility and control
system interaction of the virtual machine.
M2 Prediction of behavior of a typical machine. Further refinement until satisfactory
agreement with measurements.
M3 Optimization/redesign of mechanical and control system design to allow for
increased cutting speed at maintained or improved accuracy. Tests.
M4 Implementing the virtual machine at WJS and FA for product development
support.

S1 Literature studies. Overall scanning.

S2 Life cycle assessment for hot spots.
S3 Engineering improvements regarding the hot spots. Tests.
S4 Generation of template for sustainable design of water jet cutting machines.
S5 Investigation of possibility of environmental labeling of water jet cutting
machines. Suggestion of criteria.

C1 Continuous information exchange and investigation of interrelation.

C2 Formal workshop.
C3 Open seminar.

F1
F2
F3
M1 F4
M2 F5
M3
S1 M4
S2
S3
S4
S5
C1
C2 C2 C2 C2 C2 C2 C2
C3 C3 C3

0501 0507 0601 0607 0701 0707 0712

Figure 1. Preliminary schedule.
EFFECTIVE AND SUSTAINABLE WATER JET CUTTING
Enclosure 1 – Project Plan, Broman, BTH

Summary of Key Strengths

We believe this project has high scientific originality and high relevance to Swedish industrial
long-term competitiveness. We address a highly significant and complex challenge in the
development of a modern technology with great potential. We do this in a holistic and integrated
way by coordinating a unique combination of top level scientists and practitioners, by utilizing
our extensive experience of industrial research cooperation and by applying state-of-the-art
methods, equipment and software. In this way, we provide great potential for scientific as well as
applied breakthroughs and for transfer of knowledge and competence development.