Gopher Motorsports Gaining Competitive Edge with Jet Edge Waterjets

Determined to race its way to a Top 10 finish at the intensely competitive Michigan Formula SAE this May, the University of Minnesota’s Gopher Motorsports team has enlisted the help of waterjet manufacturer Jet Edge, Inc. to cut parts for the team’s #52 G04-16 Formula SAE race car.

St. Michael, Minnesota-based Jet Edge has been busy waterjetting a wide range of carbon composite, steel and aluminum parts for the Gophers, who are building an open-wheeled, open cock-pit race car for the Society of Automotive Engineer’s largest and most prestigious global collegiate competition May 11-14 at Michigan International Speedway (MIS). Among the parts being water jet are mounting tabs for the frame, structural inserts for the wings, and several other components, including the chain guard and brake rotors.

“Using waterjet is the fastest way to produce parts with the geometry that we’ve designed,” said Nathan Tigges, Gopher Motorsports FSAE vice president (mechanical engineering/class of 2018).
“Based upon our good experiences with waterjet cutting, we have redesigned several CNC parts to be manufactured as an assembly from waterjet parts, such as our rear bellcranks.”

The Formula SAE competition draws some of the world’s brightest engineering students, who design, manufacture, market, and ultimately race their cars at MIS, which is widely regarded as the fastest track in NASCAR.  The teams are scored on their vehicle’s performance, business logic and design presentation. Gopher Motorsports, which is the University of Minnesota’s student chapter of the Society of Automotive Engineers, has been competing in the Formula SAE since 1997, twice placing seventh out of 120 teams from around the world.  In 2015, the team placed 13th.  This year, the Gophers have their sights set on a Top 10 finish, and hope to continue outpacing their rivals from the University of Wisconsin-Madison.

“We are proud to say we’ve beaten Madison for three years running!” Tigges said.

Gopher Motorsports builds a new car every year.  They are required to change the frame geometry every year. To improve competitiveness, they also fully redesign about one-third of the system each year. Another one-third of the car needs to be revised in order to comply with the new designs and the legacy components. Prior to 2015, the team pillaged old cars for parts, but with the support of the university and local community, they are now able preserve the old models.  This allows them to preserve the team’s heritage, train new drivers and give future team members the ability to see the progression of previous designs so they can improve upon them.

Tigges noted that Jet Edge has been very helpful in saving the students time, money and material, which should give the 34-member team an edge in the important “Cost Report” event at the Michigan competition.

“We are able to produce high quality parts at low cost, both in monetary and personnel terms,” he said.  “Having a great sponsor like Jet Edge reduces the time we would otherwise spend in the shop ourselves, and lets us use money that otherwise would be spent on the same services elsewhere. That not only lets our members work on other projects, but also lets us stretch our budget. Using waterjet technologies improves our competitiveness, because it helps us reduce our estimated large-scale production cost in the ‘Cost Report’ event at competition. Rather than pricing these parts as machine parts, we are able to quote the cost of waterjet cutting, which drives down the overall budget in our Cost Report.”

Working with Jet Edge’s team has been a great learning experience, Tigges added.

“From working with Jet Edge, we have figured out ways to more efficiently utilize the raw materials that we have,” he said. “Jet Edge’s Machinist Brian Wallace helped us save half of a sheet of carbon composite material by nesting our pieces more efficiently, which really helps us out. More importantly, we will be able to implement some of those efficiencies to help out down the road!”

Wallace, who runs Jet Edge’s waterjet applications test lab, has been cutting the team’s parts on Jet Edge’s premier EDGE X-5 5-axis waterjet system.  This CNC-controlled industrial waterjet system transforms ordinary tap water and garnet abrasive into a 75,000 psi hair-thin bullet-fast abrasive waterjet that cuts precise shaped parts from virtually any material.  The system uses a Jet Edge hydraulic intensifier pump to pressurize the water, which is then forced through a jewel orifice, mixed with abrasive and focused through a nozzle.  Wallace used a .010/.030 orifice/nozzle combination and 0.5 pounds per minute of 80 grit garnet abrasive to cut the Gophers’ parts.

The honor of driving the #52 at Michigan will go to the team’s fastest drivers, said Gopher Motorsports Team member Phil Hoff, (mechanical engineering/class of 2016) who explained that the team determines its fastest drivers during actual behind the wheel time trials and by racing on a simulator that several of the team members built themselves.  Tigges noted that the team has made driver training a priority this year since both of the team’s drivers are graduating soon.

“60% of our points come from dynamic events, so it is imperative that we have a strong supply of capable drivers,” Tigges said. “It’s significantly harder to design a faster car than to train drivers to be faster.”

In addition to placing competitively in the Formula SAE, Gopher Motorsports has received several awards, including the Cummins Powertrain Excellence award.  They were one of only 10 teams worldwide chosen by Bosch for sponsorship because of the creativity they displayed in testing when they lost critical dynamometer research space but compensated by building a dyno of their own along with trackside tuning.

Both Tigges and Hoff said that participating in Gopher Motorsports has been the highlight of their mechanical engineering education.

“Working with Gopher Motorsports has given me several skills that I wouldn’t have gotten inside the classroom,” Tigges said. “It is far and away the best supplement to my engineering education that I could hope for. Whether it’s working with sponsors, to coordinating complex schedules, or even analyzing performance over several years of design, the skills I’ve learned from being a part of this organization have been a great way to prepare for industry.”

Tigges noted that the team participates in outreach events to inspire future engineering students, including the University of Minnesota’s State Fair booth, CSE Expo, STEM Expo, and other youth and high school events and visits.

Gopher Motorsports plans to finish building their #52 race car by mid-March and to unveil it in April.

Jet Edge President Jude Lague said he is very proud that Jet Edge has had the opportunity to help Gopher Motorsports.

“It’s always exciting to work with the talented engineering students at the University of Minnesota,” Lague said.  “It’s no secret that we love racing at Jet Edge.  We’ll be cheering for Gopher Motorsports to win the Michigan Formula SAE, and I can’t wait to get behind the wheel on sponsor drive day.”

Find out more about Gopher Motorsports at www.gophermotorsports.com.  

Find out more about Jet Edge waterjet systems at www.jetedge.com. 

About Gopher Motorsports
Gopher Motorsports is the University of Minnesota’s chapter in the Society of Automotive Engineers.  The team is 100 percent student led and is largely funded by industry sponsors.  Each year the team develops, builds and tests a high performance highly-engineered race car to compete in the global Formula SAE Series. The competition’s goal is to design, manufacture, market, and race an open-wheel, open-cockpit, and single-seat vehicle marketable to the weekend autocrosser. Find out more about Gopher Motorsports at www.gophermotorsports.com.

About Jet Edge, Inc.
Established in 1984, Jet Edge is a global designer and manufacturer of waterjet systems for precision cutting, surface preparation and coating removal. Jet Edge waterjets are used around the world in a broad range of industries, from the world's leading airlines to automotive, aerospace, industrial manufacturers, machine and job shops. Jet Edge waterjet systems are proudly made in the U.S.A.  For more information about Jet Edge, visit www.jetedge.com, e-mail sales@jetedge.com or call 1-800-JET-EDGE (538-3343). Follow us on Twitter @jetedge.

Water Jet or Abrasive Jet?

The term "water jet" is commonly used to describe both water-only waterjets and abrasive waterjets (abrasivejets).

Water only waterjet cutting YOXO® toys.

A pure UHP waterjet cuts soft materials with a powerful stream of water that has been pressurized up to 75,000 psi+ and forced through a tiny orifice.  Pure water only waterjets are used to cut foods such as bread, ham and carrots; as well as paper products, cardboard, carpet, foam, rubber and insulation.  They are frequently integrated into custom food processing systems, water slitting systems and shuttle systems.  Waterjets also are used like a pressure washer on steroids to blast away old coatings, paint and corrosion.

Abrasivejet cutting stainless steel at JACQUET Midwest.

When cutting hard material such as metal or stone, an abrasive (usually garnet) is added to the cutting stream, creating an abrasivejet that can cut precise parts from virtually any material, from granite, quartz and marble to difficult-to-machine super alloys such as Inconel®.  


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Water Jet Contractor AK Services Cuts 55-Inch Access in Nuclear Waste Storage Tank to Speed Cleanup of Radioactive Waste from Manhattan Project, Cold War

Water jet contractor AK Services made history recently by cutting the largest-ever access hole in an active U.S. Department of Energy radioactive waste storage tank at the DOE’s Hanford Site in southeastern Washington. The Boston-area water jet contractor cut a 55-inch diameter hole in the top of the underground tank to allow for the installation of a robotic system that will remove 247,000 gallons of radioactive and chemical waste stored in the tank during the Manhattan Project and Cold War so it can be vitrified for safer storage.

Battling freezing temperatures and the challenges of running remote-controlled ultra-high pressure water jet equipment from a 300-foot distance, AK Services used a specially engineered abrasive water jet cutting machine to make the huge cut through 15 inches of concrete and steel rebar in just 22 hours. They performed the cut at 8 inches per hour using an abrasivejet of garnet grit mixed with 3 gallons per minute of water pressurized to 48,000 psi with a Jet Edge waterjet intensifier pump.

The finished cut is the culmination of more than a year of careful planning and preparation by AK Services and Hanford Site Tank Farms prime contractor Washington River Protection Solutions to ensure worker safety and protection of the environment, said Kent Smith, WRPS deputy manager of retrieval and closure operations.

AK Services spent a year developing the water jet cutting system for the project and testing different abrasives to get consistent data for rate of advance and garnet usage, said Carl Franson, AK Services vice president of operations.

“The motion device had to be specially developed to secure itself inside a 75-inch steel riser and cut a 55-inch hole,” Franson explained. “We also needed to be able to level the motion device to make sure it did not drag the abrasivejet focusing tubes on the concrete surface.”

AK Services engineered a three-piece stainless steel motion system with two circles separated by guide bushings with a ring gear in the middle. The ring gear features four redundant Jet Edge High Flow Abrasivejet cutting heads in case of failure and is driven by a set of reduction gears and a drive motor to achieve the proper cutting rate. Pneumatically actuated rams are placed on the sides and bottom to level and secure the system.

“We were able to do the entire cut with the one lead cutting head,” Franson noted. “We used a Jet Edge High Flow Abrasivejet cutting head with a Roctec 100 focusing tube rather than the standard tungsten carbide and we ordered diamond orifices from Jet Edge to ensure the longest life possible.”

Once the system was in place, the cut itself was easy according to Franson, though not without challenges.

“The biggest challenge was running the equipment from 300 feet away,” he said. “The tank top is in a radiation area and entry to the area is regulated to the extent that anything that enters the tank farm must be scanned and cleared prior to being released out of the fenced-in restricted area. The pumps and control systems had to be outside of the restricted area to ensure they did not become contaminated with radiation and then becoming the property of the DOE. We also had the added challenge of winter weather, so we installed air dryers and used air line antifreeze to keep the system from freezing up. The UHP lines were kept running, but as the temperatures dropped, we blew them out with air.”

After the concrete plug was lifted from the tank, it was immediately wrapped in a plastic sleeve to prevent spread of contamination and then was placed in an isolated area where it is being staged for disposal at the Hanford Site. A large riser was placed in the hole to support the robotic retrieval system. According to the DOE, the riser has a shield plug bolted to its opening and thick gasket material around its outside to seal the hole. The DOE plans to begin retrieving waste from the tank this summer. The tank is one of more than 100 similar underground tanks that the DOE is cleaning out as part of its environmental cleanup effort at the Hanford Site, which was once home to nine nuclear reactors that produced plutonium for the Manahattan Project and the U.S. nuclear arsenal. Hanford is considered the most contaminated nuclear site in the U.S.

More Information

For more information about AK Services, visit http://www.akservices.com/ or call 617-884-9252.

For more information about Jet Edge, visit http://www.jetedge.com/, call 1-800-JET-EDGE (538-3343) or 763-497-8700.

About Jet Edge

Established in 1984, Jet Edge is a global designer and manufacturer of waterjet systems for precision cutting, surface preparation and coating removal. Jet Edge systems are used around the world in a broad range of industries, from the world's leading airlines to automotive, aerospace, industrial manufacturers, machine and job shops. Jet Edge waterjet systems are proudly made in the U.S.A.

Portable Water Jet Cutter Cuts Circles, Radiuses

Jet Edge introduces the Spyder Abrasivejet Radius and Circle Cutting System, a portable abrasive water jet cutting system designed for use in potentially hazardous environments.

The Spyder Abrasivejet Radius and Circle Cutting System can be set up on the side of tanks, small vessels and large diameter piping. It is held in place by vacuum cups and features a self-aligning centering pin for fast and reliable setup. Motion components are made from non-ferrous materials, and cutting head manipulators are powered by pneumatic motors, making the Spyder suitable for use in all environments. A master control panel allows operators to control the cutting head manipulators, direction, speed of travel, abrasive delivery and vacuum components from one location.

The Jet Edge Spyder Radius and Circle Cutting System is available in two sizes: 1” to 6.5” insider diameter/16” to 48” outside diameter and 3” to 12.5” inside diameter/27.5” to 56” outside diameter. The Spyder water jet cutting system is powered by Jet Edge’s 60,000 psi (4,100 bar) waterjet intensifier pumps, which are available in electric or diesel models up to 280HP.

More Information

For more information about Jet Edge waterjets, visit http://www.jetedge.com/ or call 1-800-JET-EDGE (538-3343).

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About Jet Edge

Established in 1984, Jet Edge is a global designer and manufacturer of waterjet systems for precision cutting, surface preparation and coating removal. Jet Edge systems are used around the world in a broad range of industries, from the world's leading airlines to automotive, aerospace, industrial manufacturers, machine and job shops. Jet Edge waterjet systems are proudly made in the U.S.A. For more information about Jet Edge, visit http://www.jetedge.com/, e-mail sales@jetedge.com or call 1-800-JET-EDGE (538-3343).

Michael Waltrip Racing Speeds Up Waterjet Cutting with 90,000 PSI Jet Edge X-Stream Waterjet Pump

Michael Waltrip Racing (MWR) has installed a 90,000 psi Jet Edge X-Stream xP90-100 waterjet intensifier pump at its fabrication shop in Cornelius, N.C. The pump will power MWR's Jet Edge waterjet cutting system, which it uses to make parts for its three NASCAR Sprint Cup Series teams and its NASCAR Nationwide Series team.

MWR plans to achieve much faster cutting speeds and drastically lower its operating costs with its new Jet Edge X-Stream pump. The pump produces 50% more pressure than a typical 60,000 psi waterjet intensifier pump, resulting in a 40-50% increase in productivity for many materials. As a result of these faster cutting speeds, MWR can expect to use 30% less water, 30% less power, and up to 50% less abrasive.

"These days we're all looking for ways to save time and money, and Jet Edge's X-Stream pump does both," said Nick Hughes, MWR's technical director. "We couldn't ask for anything more."

According to Hughes, MWR has been running its Jet Edge waterjet system 60 to 65 hours per week since installing it in the spring of 2008. It now waterjets 250 parts for each of its racecars. The parts are cut from a wide variety of materials ranging from ¼" Nomex® to ½" steel, and include numerous panels, mounts and chassis components, plus duct work, windows, splitter panels and much more. MWR builds about 56 cars per year, which include the #55 NAPA AUTO PARTS Toyota Camry driven by Michael Waltrip and fielded by MWR, the #00 Aaron's Dream Machine Toyota Camry driven by David Reutimann and fielded by MWR, the #47 Little Debbie® Toyota Camry driven by Marcos Ambrose fielded by JTG-Daugherty Racing through a technical alliance with MWR, and the NASCAR Nationwide Series #99 Aaron's Dream Machine Toyota Camry driven by David Reutimann fielded by MWR.

MWR has experienced tremendous productivity gains since installing its Jet Edge waterjet system, Hughes said.

"After we installed our Jet Edge last year, we increased our productivity by 50 percent and were able to get technology improvements to the racetrack two weeks faster than in the past," he said. "This resulted in some very respectable finishes that got everybody talking about Michael Waltrip Racing. It really comes down to machining time. We can cut parts a lot faster on the waterjet than on the milling center. We are also producing better quality parts and we are seeing huge reductions in material waste thanks to the Jet Edge's tight nesting capabilities."

Hughes noted that the Jet Edge waterjet was instrumental in the development of MWR's newest racecar, the Series 600.

"The Jet Edge waterjet was key to the redesign," Hughes said. "It enabled us to design and produce parts at a moment's notice. We were able to get the project done much faster and much more cost effectively than we could have in the past. As we enter our third year of Sprint Cup Series competition, there is no doubt that we will be placing even more demands on our Jet Edge waterjet. The X-Stream pump's faster cutting speeds will help us keep up with that demand."

For the latest updates on Michael Waltrip Racing's use of the Jet Edge waterjet system, and for more information about Jet Edge, visit www.jetedge.com, call 1-800-JET-EDGE (538-3343) or e-mail sales@jetedge.com. For more information about Michael Waltrip Racing, visit www.michaelwaltrip.com.

About Jet Edge
Established in 1984, Jet Edge is a global designer and manufacturer of waterjet systems for precision cutting, surface preparation and coating removal. Jet Edge systems are used around the world in a broad range of industries, from the world's leading airlines to automotive, aerospace, industrial manufacturers, machine and job shops. Jet Edge waterjet systems are proudly made in the U.S.A. For more information about Jet Edge, visit www.jetedge.com, e-mail sales@jetedge.com or call 1-800-JET-EDGE (538-3343).

Jet Edge Introducing New Mid Rail Gantry Waterjet Machine at FABTECH 2008

Jet Edge, Inc. will introduce its new Mid Rail Gantry Waterjet System at the FABTECH International & AWS Welding Show, Oct. 6-8, 2008, in Las Vegas. Look for Jet Edge in booth 4257.

< View Product Specifications.

The Jet Edge Mid Rail Gantry Waterjet System features an 8'X13' work envelope with an exposed tank that easily accommodates overhead loading. It comes standard with one abrasivejet cutting head; a second cutting head can be added to increase productivity. The Mid Rail Gantry is ball-screw driven for higher accuracy. Its sturdy heavy-wall tubular steel construction eliminates vibration and increases longevity. The Mid Rail Gantry utilizes an industrial PC controller and can be configured so that all three axes are fully programmable (Z optional). It also features direct-couple AC brushless digital servo motors and single or double carriages. Critical bearing components are protected with heavy metal covers with flexible lip seals. Like all Jet Edge products, the Mid Rail Gantry is proudly made in the U.S.A.

During FABTECH, Jet Edge also will showcase its 90,000 psi X-Stream xP90-100 and 60,000 psi iP60-50 intensifier pumps.

Capable of producing pressures in excess of 90,000psi, the 100hp X-Stream achieves much faster cutting speeds and drastically lowers operating costs compared to traditional 60,000psi pumps, enabling users to increase productivity and reduce part costs. The X-Stream produces 50% more pressure than a 60,000psi intensifier pump, resulting in a 40-50% increase in productivity for many materials. The X-Stream supports a 75,000psi continuous operating pressure. Compared to a 60,000psi pump, typical operating pressures of 75,000psi use 30% less water, 30% less power, and up to 50% less abrasive, resulting in a 40% reduction in operating costs. They typically reduce taper by up to 0.001". The X-Stream is capable of producing flow rates of 1.45gpm and supports up to a .017" orifice. Its fittings and tubing are rated for 100KSI. The X-Stream is backed by nearly 10 years of extensive research and development in hyper-pressure technology.

Featuring the most advanced technology for extended-life hydraulics, a reliable tie-rod design and easy maintenance with no threads on the high pressure cylinders, the 50-horsepower iP60-50 produces up to 60,000 psi (4,100 bar), and provides flow rates of 0 to 1.1 gallons (5 liters) per minute to a variety of cutting, surface-preparation or cleaning tools. The iP60-50 provides easy access for all service and maintenance. It features a non-threaded high-pressure cylinder with a warranty -- even on replacement cylinders, an improved performance check valve, and low torque requirements.

New Waterjet Systems Brochure!

Our new brochure features Jet Edge’s precision waterjet cutting tables, which include an expandable High Rail Gantry available in 2’ increments from 4’X4’ to 24’X14’, a Mid Rail Gantry available in sizes up to 30’X100’ and a compact Abrasive Machining Center available in 30”X30”, 30”X48” and 48”X96” models. The brochure also highlights Jet Edge’s intensifier pumps, which are available in a wide range of horse powers and capable of producing pressures from 60,000-90,000psi, as well its precision cutting accessories that include cutting heads, abrasive delivery, removal and recycling systems, and a closed loop filtration system.

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