Within the oil and gas industry on offshore installations in the North Sea, several oil wells are closing in on the brink where they no longer are being profitable to keep producing from. When that day comes the oil wells are closed off and the boreholes are plugged with cement. Before the holes can be cemented shut the companies need to remove all their equipment that has been used for underwater exploitations of the well and if applicable remove the above water installation as well. This includes removing the casing that the holes are lined with which main purpose is to prevent the hole from collapsing on the production line and to prevent oil and gas leaks into the surroundings. This thesis focuses on removal of the borehole casing.  When performing this task problems have been raised regarding corrosion on the casing couplings, making them very hard to separate. When this problem occurs, the need for an alternative method to split them is necessary. As of today this operation is performed by cold cut sawing or with a beveling machine. This is a highly time consuming task and an alternative method to perform a faster cut is wanted. This degree work investigates the possibilities of doing this using the benefits of abrasive water jet (AWJ) cutting. The major concerns on using this technic is whether it is fast enough and if it is possible to perform in accordance with the fire and explosive hazards on a hydrocarbon producing installation. As a reference the maximum cut time is set to one minute. Calculations on theoretical cutting speeds as well as physical testing on the AWJ method has been performed and evaluated. The investigations show that the method does have the possibilities of making the cut within the target time.  The work also contains a simple concept model on how the equipment could be constructed. / Inom olje- och gasindustrin på offshoreanläggningar i Nordsjön, närmar sig flera reservoarer randen där de inte längre är lönsamma att fortsätta producera från. När den dagen kommer pensioneras borrhålen och pluggas med en cementblandning. Innan hålen pluggas måste företagen ta bort all utrustning som har använts vid utvinningen av brunnen, både ovan och under ytan. Detta innefattar avlägsnande av casingen, som hålen är fodrade med, och vars huvudsakliga syfte är att förhindra att hålet kollapsar och skadar produktionsledningen, men även för att förhindra olje- och gasläckor till omgivningen. Denna avhandling fokuserar på borttagandet av casingen. När detta görs upplevs problem med att casingskarvarna är kraftigt korroderade vilket gör dem mycket svåra att separera. Detta är ett problem som efterfrågar en alternativ delningsmetod. I dag utförs den här operationen med antingen kallsågning eller med en avfasningsmaskin. Detta är en mycket tidskrävande uppgift och en metod för att utföra en snabbare delning önskas. Detta examensarbete är tänkt att undersöka möjligheterna att göra detta genom att använda fördelarna med abrasiv vattenskärning för att kapa rören. De största frågorna gällande denna metod är om den är tillräckligt snabb och om det är möjligt att utföra i enlighet med de brand- och explosionsrisker som finns på en kolväteproducerande installation. Som referens är målet för maximal skärtid satt till en minut. Beräkningar på teoretiska skärhastigheter samt fysiska tester på metoden har utförts och utvärderats. Undersökningarna visar på att metoden har möjligheter att göra snittet inom utsatt tid. Arbetet innehåller också en enkel konceptmodell på hur utrustningen skulle kunna konstrueras.

Abrasive waterjet (AWJ) cutting is one of the most recently developed manufacturing technologies. It is superior to many other cutting techniques in processing various materials, particularly in processing difficult-to-cut materials. This technology is being increasingly used in various industries. However, its cutting capability in terms of the depth of jet penetration and kerf quality is the major obstruction limiting its further applications. More work is required to fully understand the cutting process and cutting mechanism, and to optimise cutting performance. This thesis presents a comprehensive study on the controlled nozzle oscillation technique aiming at increasing the cutting performance in AWJ machining. In order to understand the current state and development in AWJ cutting, an extensive literature review is carried out. It has found that the reported studies on controlled nozzle oscillation cutting are primarily about the use of large oscillation angles of 10 degrees or more. Nozzle oscillation in the cutting plane with such large oscillation angles results in theoretical geometrical errors on the component profile in contouring. No published attempt has been found on the study of oscillation cutting under small angles although it is a common application in practice. Particularly, there is no reported research on the integration of nozzle oscillation technique into AWJ multipass cutting, which is expected to significantly enhance the cutting performance. An experimental investigation is first undertaken to study the major cutting performance measures in AWJ single pass cutting of an 87% alumina ceramic with controlled nozzle oscillation at small angles. The trends and characteristics of cutting performance quantities with respect to the process parameters as well as the science behind which nozzle oscillation affects the cutting performance have been analysed. It has been shown that as with oscillation cutting at large angles, oscillation at small angles can have an equally significant impact on the cutting performance. When the optimum cutting parameters are used for both nozzle oscillation and normal cutting, the former can statistically increase the depth of cut by 23% and smooth depth of cut by 30.8%, and reduce kerf surface roughness by 11.7% and kerf taper by 54%. It has also been found that if the cutting parameters are not selected properly, nozzle oscillation can reduce some major cutting performance measures. In order to correctly select the process parameters and to optimise the cutting process, the mathematical models for major cutting performance measures have then been developed. The predictive models for the depth of cut in both normal cutting and oscillation cutting are developed by using a dimensional analysis technique. Mathematical models for other major cutting performance measures are also developed with the aid of empirical approach. These mathematical models are verified both qualitatively and quantitatively based on the experimental data. The assessment reveals that the developed models conform well to the experimental results and can provide an effective means for the optimum selection of process variables in AWJ cutting with nozzle oscillation. A further experimental investigation of AWJ cutting of alumina ceramics is carried out in order to study the application of AWJ oscillation technique in multipass cutting. While high nozzle traverse speed with multipass can achieve overall better cutting performance than low traverse speed with single pass in the same elapsed time, it has been found that the different combination of nozzle traverse speed with the number of passes significantly affects cutting process. Optimum combination of nozzle traverse speed with the number of passes is determined to achieve maximum depth of cut. It has also demonstrated that the multipass cutting with low nozzle traverse speed in the first pass and a comparatively high traverse speed for the following passes is a sensible choice for a small kerf taper requirement. When nozzle oscillation is incorporated into multipass cutting, it can greatly increase the depth of cut and reduce kerf taper. The predictive models for the depth of cut in both multipass normal cutting and multipass oscillation cutting are finally developed. With the help of dimensional analysis, the models of the incremental cutting depth for individual pass are derived based on the developed depth of cut models for single pass cutting. The models of depth of cut for a multipass cutting operation are then established by the sum of the incremental cutting depth from each pass. A numerical analysis has verified the models and demonstrated the adequacy of the models' predictions. The models provide an essential basis for the development of optimization strategies for the effective use of the AWJ cutting technology when the multipass cutting technique is used with controlled nozzle oscillation.

No description available.

Abrasive waterjet (AWJ) cutting is a versatile technique which has been effectively applied to rock cutting since the late 1980s. The complexity of the interaction between the waterjet and the rocks complicates the thorough understanding of the phenomena involved in AWJ rock cutting. On one hand, rocks are complex materials which are generated through different processes in an uncontrolled environment without human interference. On the other hand, the AWJ acts with high velocity and turbulence, complicating direct observation and the perception of details. In this respect, the present research aims to contribute to the study of AWJ cutting applied to rocks, including the analysis of qualitative and quantitative information, both of great importance regarding the study of complex materials. Concerning quantitative data, special attention is given to the investigation of the cutting efficiency, which can be analyzed by observing conditions in which the higher cutting rate is associated with the minimum energy provided by the AWJ machine per removed volume of rock. Moreover, the real efficiency can be analyzed through the investigation of the conditions in which the major part of the energy provided by the AWJ machine is used effectively for rock cutting, deducting dissipation losses. The effects of varying traverse velocity and pump pressure on cutting parameters were also investigated, in addition to the influence of rock properties on the effective energy of cutting. The effective energy was calculated based both on the specific energy and specific destruction work of the materials. With respect to the qualitative investigation, petrographic and scanning electron microscopy (SEM) analyses were conducted in order to visualize and better understand the different effects of cutting on the studied rocks. Cutting tests with a traverse velocity of 200 mm/min and a pump pressure of 400 MPa presented the most efficient rock cutting regarding both methods of efficiency analysis. Dry density and tensile strength presented fair correlations with the effective cutting energy, while the modulus ratio presented the best correlations. It was observed that brittleness plays a key role in the understanding of the phenomena involved in AWJ rock cutting. / O jato d\'água abrasivo (AWJ) é uma técnica versátil que tem sido efetivamente aplicada ao corte de rochas desde o fim da década de 1980. A complexidade da interação entre o jato e as rochas dificulta a compreensão detalhada dos fenômenos envolvidos no corte de rochas com AWJ. Por um lado, rochas são materiais complexos gerados em ambientes sem interferência humana. Por outro lado, o AWJ age com alta velocidade e turbulência, dificultando a observação direta do procedimento. Assim, a presente tese de doutorado visa a contribuir com o estudo do corte de rochas com AWJ, incluindo análises de dados qualitativos e quantitativos, ambos de grande importância em estudos de materiais complexos. A análise quantitativa possui foco na investigação da eficiência de corte, a qual pode ser analisada por meio da observação das condições em que há a maior taxa de corte associada à mínima energia fornecida pelo AWJ por volume de rocha removido. Além disso, a eficiência real do corte pode ser analisada a partir da investigação das condições em que a maior parte da energia fornecida pelo AWJ é usada para efetivamente cortar a rocha, descontando perdas por dissipação. Os efeitos da variação da velocidade transversal de corte e da pressão da bomba nos parâmetros de corte também foram investigados, além da influência das propriedades das rochas na energia efetiva de corte. A energia efetiva de corte, denominada energia relativa de formação da ranhura (EKR), foi calculada com base na energia específica e no trabalho de destruição específico dos materiais. Análises de microscopia eletrônica de varredura (SEM) e petrografia foram conduzidas para visualizar e compreender melhor os diferentes efeitos do corte nas rochas estudadas. Os testes de corte realizados com velocidade transversal do bocal de 200 mm/min e pressão da bomba de 400 MPa apresentaram as melhores eficiências de corte considerando-se ambos os métodos de análise de eficiência. Dentre as propriedades das rochas investigadas, a massa específica e a resistência à tração por compressão diametral apresentaram correlações razoáveis com EKR, enquanto que o modulus ratio apresentou as melhores correlações. Observou-se que a ruptibilidade possui papel fundamental na compreensão dos fenômenos envolvidos no corte de rochas com AWJ.

An experimental investigation has been undertaken to study the depth of cut in multipass abrasive waterjet (AWJ) cutting of an 87% alumina ceramic with controlled nozzle oscillation. The experimental data have been statistically analysed to study the trends of the depth of cut with respect to the process parameters. It has been found that multipass cutting with controlled nozzle oscillation can significantly increase the depth of cut. Within the same cutting time and using the same cutting parameters other than the jet traverse speed, it has been found that multipass cutting with nozzle oscillation can increase the depth of cut by an average of 74.6% as compared to single pass cutting without nozzle oscillation. Furthermore, a multipass cutting with higher nozzle traverse speeds can achieve a larger depth of cut than a single pass cutting at a low traverse speed within the same cutting time. A recommendation has been made for the selection of appropriate process parameters for multipass cutting with nozzle oscillation. In order to estimate the depth of cut on a mathematical basis, predictive models for the depth of cut in multipass cutting with and without nozzle oscillation have been developed using a dimensional analysis technique. The model development starts with the models for single pass cutting which are then extended to multipass cutting where considerations are given to the change of the actual standoff distance after each pass and the variation of kerf width. These predictive models has been numerically studied for their plausibility by assessing their predicted trends with respect to the various process variables, and verified qualitatively and quantitatively based on the experimental data. The model assessment reveals that the developed models correlate very well with the experimental results and can give adequate predictions of this cutting performance measure in process planning.

An experimental investigation has been undertaken to study the depth of cut in multipass abrasive waterjet (AWJ) cutting of an 87% alumina ceramic with controlled nozzle oscillation. The experimental data have been statistically analysed to study the trends of the depth of cut with respect to the process parameters. It has been found that multipass cutting with controlled nozzle oscillation can significantly increase the depth of cut. Within the same cutting time and using the same cutting parameters other than the jet traverse speed, it has been found that multipass cutting with nozzle oscillation can increase the depth of cut by an average of 74.6% as compared to single pass cutting without nozzle oscillation. Furthermore, a multipass cutting with higher nozzle traverse speeds can achieve a larger depth of cut than a single pass cutting at a low traverse speed within the same cutting time. A recommendation has been made for the selection of appropriate process parameters for multipass cutting with nozzle oscillation. In order to estimate the depth of cut on a mathematical basis, predictive models for the depth of cut in multipass cutting with and without nozzle oscillation have been developed using a dimensional analysis technique. The model development starts with the models for single pass cutting which are then extended to multipass cutting where considerations are given to the change of the actual standoff distance after each pass and the variation of kerf width. These predictive models has been numerically studied for their plausibility by assessing their predicted trends with respect to the various process variables, and verified qualitatively and quantitatively based on the experimental data. The model assessment reveals that the developed models correlate very well with the experimental results and can give adequate predictions of this cutting performance measure in process planning.

Abrasive waterjet (AWJ) cutting is a versatile technique which has been effectively applied to rock cutting since the late 1980s. The complexity of the interaction between the waterjet and the rocks complicates the thorough understanding of the phenomena involved in AWJ rock cutting. On one hand, rocks are complex materials which are generated through different processes in an uncontrolled environment without human interference. On the other hand, the AWJ acts with high velocity and turbulence, complicating direct observation and the perception of details. In this respect, the present research aims to contribute to the study of AWJ cutting applied to rocks, including the analysis of qualitative and quantitative information, both of great importance regarding the study of complex materials. Concerning quantitative data, special attention is given to the investigation of the cutting efficiency, which can be analyzed by observing conditions in which the higher cutting rate is associated with the minimum energy provided by the AWJ machine per removed volume of rock. Moreover, the real efficiency can be analyzed through the investigation of the conditions in which the major part of the energy provided by the AWJ machine is used effectively for rock cutting, deducting dissipation losses. The effects of varying traverse velocity and pump pressure on cutting parameters were also investigated, in addition to the influence of rock properties on the effective energy of cutting. The effective energy was calculated based both on the specific energy and specific destruction work of the materials. With respect to the qualitative investigation, petrographic and scanning electron microscopy (SEM) analyses were conducted in order to visualize and better understand the different effects of cutting on the studied rocks. Cutting tests with a traverse velocity of 200 mm/min and a pump pressure of 400 MPa presented the most efficient rock cutting regarding both methods of efficiency analysis. Dry density and tensile strength presented fair correlations with the effective cutting energy, while the modulus ratio presented the best correlations. It was observed that brittleness plays a key role in the understanding of the phenomena involved in AWJ rock cutting. / O jato d\'água abrasivo (AWJ) é uma técnica versátil que tem sido efetivamente aplicada ao corte de rochas desde o fim da década de 1980. A complexidade da interação entre o jato e as rochas dificulta a compreensão detalhada dos fenômenos envolvidos no corte de rochas com AWJ. Por um lado, rochas são materiais complexos gerados em ambientes sem interferência humana. Por outro lado, o AWJ age com alta velocidade e turbulência, dificultando a observação direta do procedimento. Assim, a presente tese de doutorado visa a contribuir com o estudo do corte de rochas com AWJ, incluindo análises de dados qualitativos e quantitativos, ambos de grande importância em estudos de materiais complexos. A análise quantitativa possui foco na investigação da eficiência de corte, a qual pode ser analisada por meio da observação das condições em que há a maior taxa de corte associada à mínima energia fornecida pelo AWJ por volume de rocha removido. Além disso, a eficiência real do corte pode ser analisada a partir da investigação das condições em que a maior parte da energia fornecida pelo AWJ é usada para efetivamente cortar a rocha, descontando perdas por dissipação. Os efeitos da variação da velocidade transversal de corte e da pressão da bomba nos parâmetros de corte também foram investigados, além da influência das propriedades das rochas na energia efetiva de corte. A energia efetiva de corte, denominada energia relativa de formação da ranhura (EKR), foi calculada com base na energia específica e no trabalho de destruição específico dos materiais. Análises de microscopia eletrônica de varredura (SEM) e petrografia foram conduzidas para visualizar e compreender melhor os diferentes efeitos do corte nas rochas estudadas. Os testes de corte realizados com velocidade transversal do bocal de 200 mm/min e pressão da bomba de 400 MPa apresentaram as melhores eficiências de corte considerando-se ambos os métodos de análise de eficiência. Dentre as propriedades das rochas investigadas, a massa específica e a resistência à tração por compressão diametral apresentaram correlações razoáveis com EKR, enquanto que o modulus ratio apresentou as melhores correlações. Observou-se que a ruptibilidade possui papel fundamental na compreensão dos fenômenos envolvidos no corte de rochas com AWJ.

The project is elaborated in frame of engineering studies branch 2303T002. The project is submitting suggestion of convenient technologies of production for submitted flat sheet metal part 11 375. There are proposed a number of variants of production method, namely: production on sequence shearing tool, production by means of plasma machine, laser machines and machines for watejets cutting. Particular part is designed for the production quantity of 380 000 pieces per year. Based on the literary study of the shear and calculations, there were designed shearing tool for given part. For this tool the press CDCH 3000 P was selected (producer HESSE+CO Maschinenfabrik GmbH), with nominal force 3 000 kN. In the work there are included necessary calculations for all variants including technological and economical evaluation.

The thesis primarily deals with the optimization of laser cutting center for coated aluminium sheet cutting and with the subsequent comparison of measured results and a sample made using waterjet cutting. The thesis is divided in two parts, the theoretical part followed by the practical one. The theoretical section is concerned with the unconventional technologies used, with their general analysis, design, history and utilization for industrial appliances. Main parts of this thesis deals with classification of particular cutting principles and their specific description. The theoretical part contains also classificaton of aluminium alloy, description of surface texture measurement and explanation of basics terms used for roughness measurement. The practical section is concerned with the particular task solution and with all knowledge used for optimization and evaluation of laser cutting. This part contains the measurement results, the measured material, the machines and devices used and also the technical and economical evaluation of this thesis content. The overall evaluation of the laser cutting optimization of specific component is mentioned in the experiment outcome evaluation article.