The Institution of Engineers

The Institution of Engineers (India)_ Project Report
PROJECT REPORT ON
DESIGN AND FABRICATION OF
WORKING MODEL
OF ABASIVE JET MACHINE
By
GADADHAR DEY
(ST-635979-0)
WINTER 2015(Mechanical Engineering)
Under the esteem guidance of
Mr. Surendara Kumar Thawait(FIE),

F-016816-1
The Institution of Engineers (India)

8,Gokhale Road,Kolkata,700020,india
Page 01 of 34
Gadadhar Dey (ST 635979-0) Mechanical Engineering
INDEX
1. Certificate of Originality 3
2. Acknowledgement 4
3. Synopsis 5
Total Marks - 100
Mark Obtained -
Project Guide - Mr. Surendra Kumar Thawait
Membership No. - F-016816-1
PROJECT REPORT
1. Title of the project 8

2. Table of contents 9
3. List of table and figures 11
4. Objectives 12
5. Abstract 12
6. Methodology of the study 13
7. Statement of problems 13
8. Input data/structure 14
9. Components and their Design 22
10. Result 32
11. Conclusion 32
12. Scope of Future Study 33
13. References 34
Page 02 of 34
CERTIFICATE OF ORGINALITY
I hereby declare that myself Gadadhar dey , a senior Technician

Member ( ST 635979 0 , Mechanical Engineering ) of the institution
Of engineers ( India) Kolkata , have completed my project titled DESIGN
AND FABRICATION OF WORKING MODEL OF ABRASIVE JET MACHINE at
M/s. Taneja Aerospace and Aviation Ltd,Tamilnadu . I also declare that
this above mentioned work carried out by me Is original one and it has
not been sent earlier to any other institution for Fulfillment of the
requirement of a course of study .
Gadadhar Dey
(ST -635979-0 )
Countersigned by
(Mr . Surendra Kumar Thawait)

F.I.E. (F-016816-1)
Page 03 of 34

ACKNOLEDGEMENT
I am proud to acknowledge the technical direction/guidance provided by

Mr. Surendra Kumar Thawait, FIE, Member of Institution of engineers
(india) in this project. I was blessed to get a person like him , with robust
Technical background and patience, in grooming up this project report
At every level right from conception to the final stage , and for guiding
Me to study the various parameters and Setting the pace of this project .
I must also acknowledge the technical support offered by

Machine shops member of M/s Taneja Aerospace and Aviation Ltd. in
this project . They have given me an insight of the Abrasive Jet
Machines and verified the Observations observed by me .
I also acknowledge the assistance rendered by my seniors and technicians

to carry out and successfully Complete the above project .
Gadadhar Dey
(ST 635979-0)
Page 04 of 34
SYNOPSIS
1.TITLE OF THE PROJECT :

Design and Fabrication of working model of abrasive jet machine
2 .OBJECTIVE OF THE PROJECT :
Abrasive Jet Machining (AJM) is the process of material removal from a

work piece by the application of a high speed stream of abrasive particles
carried in a gas or air medium from a nozzle. The material removal
process is mainly by erosion.
3.RATIONALE OF THE PROJECT :

The AJM will chiefly be used to cut shapes in hard and brittle materials
like glass, ceramics etc. the machine will be automated to have 3 axes
travel. The different components of AJM are Compressor, Vibrator,
dehumidifier, Pressure Regulato , and Dust filter, Nozzle, Pressure gauge
etc. The different components are selected after appropriate design
calculations.
In this project, a model of the Abrasive Jet Machine is designed

using available hardware and software etc. taking into consideration of
commercially available components.
Page 05 of 34
4.METHEDOLOGY TO BE USED FOR CARRYING OUT THE

STUDY:
The methodology comprises of following:
A. Collection of data regarding abrasive particles .

B. Comparing the datas on graphs.
C. Study of improving the material removal rate
D. Optimum utilization of abrasive particles.
E. Modification of existing technology.
5.EXPECTED CONTRIBUTION FOM THE STUDY:
The outcome of the study is to suggest methods of improving material

removal rate of Abrasive jet machine.
6.LIST OF ACTIVITIES TO BE CARRIED OUT TO COMPLETE THE

PROJECT:
The following list of activities to be carried out with their expected date
of completion.
A. Collection of Sub-Critical Data.
B.Collection of Super-Critical Data.
Page 06 of 34
C. Modification of the process to improve the quality of material

removal rate .
7.PLACE/EQUIPMENTS REQUIRED & PLANNING OF

ARRANGEMENTS :
Location of the project
This project will be carried out at M/s. Taneja Aerospace And Aviation
Ltd.,Machine shop , Hosur ,Tamilnadu .
8.PROBLEM ENVISAGED IN CARRYING OUT THE PROJECT:
A. The abrasive material may accumulate at nozzle and fail the

process if moisture is present in the air.
B. Occasional plugging of mixing tube: Usually caused by dirt or
large particles in abrasive.
C. Wear, misalignment, and damage to the nozzle.
Prepared by: Approved by:
Gadadhar Dey Mr. Surendra Kumar Thawait

(ST 635979-0) (F-016816-1)
Page 07 of 34
PROJECT REPORT
1.TITLE OF THE PROJECT :

Design and Fabrication of working model of abrasive jet
machine.
NAME OF THE STUDENT : Gadadhar Dey
MEMBERSHIP NO. : ST-635979-0
NAME OF THE PROJECT GUIDE: Surendra Kumar Thawait
MEMBERSHIP NO. : F-016816-1
Page 08 of 34

2.TABLE OF CONTENTS:
S/N. TITLE PAGE NO.

1. Title of the project 08
2. Table of contents 09
3. List of tables and figures 11
4. Objectives 12
5. Abstract 12
6. Methodology of study 13
7. Statement of the problem 13
8. Input data/structure 14
8.1 Introduction 14
8.2 Equipments 14
8.3 Different variables in abrasive jet machine 16
8.4 Variable Characteristics 17
8.5 Advantages 18
8.6 Limitations 18
8.7 Applications 18
Page 09 of 34

8.8 Literature Review 19

9. Components and their Design 22
9.1 Compressor 22
9.2 FR Unit 23
9.3 Vibrating Unit 25
9.3.1 Abrasive Container 25
9.3.2 Cam 26
9.3.3 Induction Motor 27
9.4 Nozzle 29
9.5 Total Assembly 30
9.6 Cost Estimation 31
10. Result 32
11. Conclusion 32
12. Scope of future study 33
13 References 34
Page 10 of 34

3.LIST OF TABLES AND FIGURES:
List of Tables
Table 1 Characteristics of different variables
Table 2 Cost calculation
List of Figures
Fig. 1 Schematic layout of abrasive jet machine
Fig 2 Effect of process parameters on erosion rate
Fig 3 Crack propagation during abrasive cutting of glass
Fig. 4 Filter regulator unit
Fig. 5 Abrasive container
Fig. 6 Cam
Fig. 7 Vibration Assembly
Fig. 8 Cut section of Nozzle
Fig 9 Position of nozzle
Page 11 of 34
4.OBJECTIVES :

Abrasive Jet Machining (AJM) is the removal of material from a work
piece by the application of a high speed stream of abrasive particles
carried in gas medium from a nozzle. The AJM process differs from
conventional sand blasting in that the abrasive is much finer and the
process parameters and cutting action are carefully controlled.
5.ABSTRACT :
Abrasive Jet Machining (AJM) is the process of material removal from
a work piece by the application of a high speed stream of abrasive
particles carried in a gas or air medium from a nozzle. The material
removal process is mainly by erosion. The AJM will chiefly be used to
cut shapes in hard and brittle materials like glass, ceramics etc. the
machine will be automated to have 3 axes travel. The different
components of AJM are Compressor, Vibrator, dehumidifier, Pressure
Regulator, and Dust filter, Nozzle, Pressure gauge etc. The different
components are selected after appropriate design calculations.
In this project, a model of the Abrasive Jet Machine is designed using
available hardware and software etc. taking into consideration of
commercially available components. Care has been taken to use less
page 12 of 34

fabricated components rather than directly procuring them, because, the

lack of accuracy in fabricated components would lead to a diminished
performance of the machine.
6.METHEDOLOGY OF STUDY:
The methodology in this project involves understandings of the
following Variables:-
a. Carrier gas
b. Types of abrasive
c. Size of abrasive grain
d. Velocity of abrasive jet
e. Flow rate of abrasive
f. Work material
g. Geometry, composition and material of nozzle
h. Nozzle work distance (stand off distance)
7.STATMENTS OF THE PROBLEMS :
Improvement in the following areas
a. Reduction in Capital cost
b. Ability to cut intricate holes shape in materials of any hardness.
c. Ability to cut heat sensitive material without damage.
Page 13 of 34

8.INPUT DATA/STRUCTURE:
8.1 INTRODUCTION: Abrasive Jet Machining (AJM) is the removal
of material from a work piece by the application of a high speed stream
of abrasive particles carried in gas medium from a nozzle. The AJM
process differs from conventional sand blasting in that the abrasive is
much finer and the process parameters and cutting action are carefully
controlled.
The process is used chiefly to cut intricate shapes in hard and brittle
materials which are sensitive to heat and have a tendency to chip easily.
The process is also used for deburring and cleaning operations. AJM is
inherently free from chatter and vibration problems. The cutting action
is cool because the carrier gas serves as a coolant.
8.2 EQUIPMENTS: A schematic layout of AJM is shown in Fig1.
The filtered gas, supplied under pressure to the mixing chamber

containing the abrasive powder and vibrating at 50 c/s, entrains the
abrasive particle and is the passed into a connecting hose. This abrasive
and gas mixture emerges from a small nozzle at high velocity.
The abrasive powder feed rate is controlled by the amplitude of
vibration of the mixing chamber. A pressure regulator controls the gas

Page14 0f 34
flow and pressure.The nozzle is mounted on a fixture. Either the work

piece or the nozzle is moved by cams pantograph or other suitable
mechanisms to control the size and shape of the cut. Hand operation is
sometimes adequate to remove surface contaminations or in cutting
where accuracy is not very critical. Dust removal equipment is
necessary to protect the environment. Commercial bench mounted units
including all controls, motion producing devices, and dust control
equipment are available.

Page 15 of 34
The major components are:

a. Air compressor.
b. Air filter.
c. Dehumidifier.
d. Pressure Gauge.
e. Pressure Regulator.
f. Vibrator or Mixer.
g. Nozzle.
h. Arrangement to hold the work piece.
8.3 DIFFERENT VARIABLES IN ABRASIVE JET MACHINE:

The variables that influence the rate of metal removal and accuracy of
machining in this process is:
a. Carrier gas and work material
b. Types of abrasive
c. Size of abrasive grain.
d. Velocity of abrasive jet.
e. Flow rate of abrasive.
g. Geometry, composition and material of nozzle.
h. Nozzle work distance (stand off distance)

page 16 of 34
8.4 CHARECTERSTICS OF DIFFERERNT VARIABLES:

Medium Air , CO2 ,N2
Abrasive SiC, Al2O3 (of size 20 to
50 )
Flow rate of abrasive 3 to 20 gram/min
Velocity 150 to 300 m/min
Pressure 2 to 8 kg/cm2
Nozzle size 0.40 to 0.80 mm
Material of Nozzle Tungsten carbide,
Sapphire
Nozzle life 12 to 300 hr
Stand off distance 0.25 to 15 mm (8mm
generally)
Work material Non Metals like glass,
ceramics,and
granites.
Metals and alloys of hard
materialslike
germanium,
silicon etc
Application Drilling, cutting, cleaning
Table 1 Characteristics of different variables

Page 17 of 34
8.5 ADVANTAGES:
a. Low capital cost
b. Ability to cut intricate holes shape in materials of any hardness.
c. Ability to cut heat sensitive material without damage.
d. As no heat is generated in the process, no change in microstructure
8.6 LIMITATIONS:
a. Material removal rate is low and hence its application is limited.
b. Embedding of the abrasive in the work piece surface may occur while
machining softer material.
c. The abrasive material may accumulate at nozzle and fail the process if
moisture is present in the air.
e. Occasional plugging of mixing tube: Usually caused by dirt or large
particles in abrasive.
f. Wear, misalignment, and damage to the nozzle.
8.7 APPLICATION: The major application of Abrasive jet machining
process is in the machining of essentially brittle materials and heat
sensitive materials like glass, quartz, sapphire, semiconductor materials,
mica and ceramics. It is also used in cutting slot, thin sections, countering,
drilling, for producing integrate shapes in hard and brittle materials. It is
often used for cleaning and polishing of plastics nylon and Teflon
components. Delicate cleaning, such as removal of smudges from antique
documents, is also easily done with Abrasive jet machining.

Page 18 of 34
8.8 LITREATURE SURVEY: The literature study of Abrasive Jet

Machine reveals that the Machining process was started a few decades
ago. Till date there has been a through and detailed experiment and
theoretical study on the process. Most of the studies argue over the
hydrodynamic characteristics of abrasive jets, hence ascertaining the
influence of all operational variables on the process effectiveness
including abrasive type, size and concentration, impact speed and angle of
impingement. Other papers found new problems concerning carrier gas
typologies, nozzle shape, size and wear, jet velocity and
pressure,standoffdistance (SOD), or nozzletipdistance (NTD).
These papers express the overall process performance in terms of material
removal rate, geometrical tolerances and surface finishing of work pieces,
as well as in terms of nozzle wear rate. Finally, there are several
significant and important papers which focus on either leading process
mechanisms in machining of both ductile and brittle materials, or on the
development of systematic experimentalstatistical approaches and
artificial neural networks to predict the relationship between the settings
of operational variables and the machining rate and accuracy in surface
finishing.
(Ref9)The erosion of brittle materials by solid micro-particles is a

complex process in which material is removed from the target surface by
brittle fractures. The rate of material removal is one of the most important
quantities for a machining process. Predictive mathematical models for

the erosion rates in micro-hole drilling and micro-channel cutting on
glasses with an abrasive air jet are developed. A dimensional analysis
Page 19 of 34
technique is used to formulate the models as functions of the particle

impact parameters, target material properties and the major process
parameters that are known to affect the erosion process of brittle
materials. The effect of various parameters like abrasive mass flow rate,
air pressure and standoff distance on erosion rate is shown by following
graphical presentation.

Page 20 of 34
The AJM has been applied to rough working such as deburring and rough
finishing. With the increase of the needs for machining of ceramics,
semiconductors, electronic devices and LCDs, micro-AJM has become a
useful technique for micro machining. Experimental results showed good
performance in micro-grooving of glass; however, the size of machined
groove increased about 24 m. With the fine-tuning the compensation
for film wear, micro-AJM could be effectively applied to the micro-
machining of semiconductors, electronic devices and LCD. The crack
propagation during impact of abrasive particles on machining material is
given below:

Page 21 of 34
9.COMPONENTS AND THEIR DESIGN

9.1 COMPRESSOR: Compressor is a device that converts power
(usually from an electric motor, a diesel engine or a gasoline engine) into
kinetic energy by compressing and pressurizing air or gas which can be
released according to use. In this project, a reciprocating air compressor
of 2kW is used to produce compressed air up to the pressure of 150 psi
and having storage tank which has storage capacity of 50 liters.

Page 22 of 34
9.2 FR UNIT (Dehumidifier): The FRL Unit (Air Filter Regulator

Lubricator unit) which is otherwise called the moisture separator or
dehumidifier is required for separating the moisture from air.
Atmospheric air always contains some water vapors in it. As the air with
high velocity is blown from the nozzle there is an abrupt rise in pressure
which converts water vapors into moisture. The moisture makes the
abrasive particles to agglomerate and this clogs the outlet of the Nozzle.
To avoid this clogging moisture separator should be used before abrasive
particles are mixed with compressed air. Different FRL Units are
available commercially.

Page 23 of 34

Page 24 of 34
9.3 THE VIBRATING UNIT: Vibrating Unit is used for mixing the air
with the abrasive particles (Al2O3). The Abrasive particles are stored in a
container through which air is flown. The particles are agitated by means
of a cam and motor arrangement. The rotation of cam results in vibration
in the abrasive container. The flow rate of abrasive materials can be
controlled by manipulating the rotational speed of the motor. The abrasive
container will have one inlet and one outlet for air passage and will be
vertically suspended from a hinged joint. So the Vibrating Unit consists
of following parts
i. Abrasive container
ii. Cam
iii. Induction Motor
9.3.1 ABRASIVE CONTAINER:
Abrasive container is fabricated by a hollow cylindrical thick metallic
pipe of 60mm diameter and 140mm height. Two circular pipes of internal
diameter 18mm is dipped from the top and welded, which would act as
input for compressed air and output for mixture of compressed air and
abrasive particles. The length of input pipe dipped is kept long to uniform
circulation of compressed air into the container.

Page 25 of 34
9.3.2 CAM:
Cam is fixed with shaft of the induction motor. The profile of the cam is
taken to be a circular one. The distance between two centers as shown in

fig26 is 5mm. When the motor rotates; it makes the container to

vibrate. Width of cam is 35mm.
Page 26 of 34
9.3.3 INDUCTION MOTOR:

Induction motor used in this project is Single phase AC Induction motor
of 0.5 watt. This motor is used to provide rotational motion to the Cam
attached with it. The installed induction motor has speed of 600 rpm.
Page 27 of 34

Page 28 of 34

9.4 NOZZLE : A standard high carbon high chromium cylindrical rod
was cut into required length by power hacksaw. The external diameter
was then brought to 20mm by turning it in lathe and then the tip was
made by tapering one end by the same lathe. A blind hole of approximate
depth25mm was made on the planner face of the rod by means of a 12mm
drill bit in a drilling machine. The end of the blind hole forms a shape of
118 degree taper because of the tool tip angle. Internal threading was
made by 12mm tap. Then the tip of the nozzle is diameter drilled to
approximate diameter of 1mm.
Page 29 of 34

9.5 TOTAL ASSEMBLY: Finally all parts are assembled with hose
pipes and clamps. First of all compressor is joined with FR unit which is
acting as filter, dehumidifier and regulator. Then further FR is attached
with the abrasive container with pipes. Then from the output of abrasive
container a pipe is attached to the nozzle which will help to transport
compressed air and abrasive mixture to the nozzle. Along with it
Induction motor is also attached to the cam and this assembly is provided
to abrasive container as given in the picture below:
Page 30 of 34

9.6 COST CALCULATION:
S No. Name of Quantity Cost Total
Item Per cost of
Unit item
1. Reciprocating 1 7900 7900
Air
Compressor
2. FR unit 1 1100 1100
3. Abrasive 1 450 450
Container
4. Induction 1 950 950
Motor
5. Abrasives 3 kg 60 180
6. Accessories - 2100 2100
7. Other - 1400 1400
Expenses
TOTAL 13130
Table 2 Cost calculation
Page 31 of 34

10. RESULT: Following outcome observed during using of this abracive
jet machine:-
a. Reduction in capital cost.
b. Can cut intricate holes shape in materials of any hardness.
c. Can cut heat sensitive material without damage.
d. No heat is generated in the process, so no change in microstructure.
11.CONCLUSION:
In this project a complete design of the Abrasive Jet Machine is given.
The total assembly is designed taking in account of currently available
components in the market. The designing and assembling of very large
number of components was a tremendous task and was completed on
time. However because of some parts couldnt be purchased the whole
assembly was limited to some basic manufacturing operation.
The project can go beyond its current position and capabilities by
employing automation into it. This can be done by using stepper motors
or DC servo motors interfaced with standard PCI controllers or
standalone controllers. 2D profiles can be converted into standard
Gcodes and Mcodes and that can be sent to the machine to perform
automated machining.
Page 32 of 34

12.SCOPE OF FUTURE STUDY:

There is much scope of future research in the AJM which can be perform
by changing the nozzle design, nozzle pressure, SOD(Standoff Distance),
etc. and Comparing the effect of various parameters on MRR(Material
Removal Rate) on various metals like composites, ceramics, by
improving the Kerf Characteristics, Integration of AJM with CNC, Model
comparison, etc. The Optimized models can be developed by using
various optimization techniques, and also the surface characteristic
measurements are yet to be performed and also from fig 11 We can see
the area of researches performing on abrasive jet machine(AJM)
Fig.11 Pi-Chart indicates the areas of Researches performed on Abrasive

jet machining.
Page 33 0f 34
13.REFERENCES:
1. Ingulli.C.N,Abrasive Jet MachiningTool and Manufacturing Engg

Vol-59 p-28-1967.
2. M L Neema and P C Pandey. 'Erosion of Glass When Act Upon by an

Abrasive Jet' Proceedings of InternationGI ConfneTice on Wear of
Materials,
1977.
3. A Bhattacharya. 'New Technology'. The Institution of Engineers

(India), 1976.
4. Dr.A. k. Paul &R. K. Roy some studies on Abrasive jet machining the
Journal of the Institution of Engineers (India) Vol 68 part PE 2 November
1987.
5. A P Verma and G K Lal. 'An Experimental Study of Abrasive Jet

Machining'. International Journal of Machine Tool Design and Research,
Vol 24,-110 I, 1984.
6. I Finnie. 'Erosion of Surface by Solid Particles'. Welr, vol 3,1960.
7. P K Sarkar and P C Pandey. 'Some Investigations on the Abrasive Jet

Machining', Journal of the Institution of Engineers (India), Vol 56, ME 6,
1976.
8. V. K. Jain, S. K. Choudhury and K. M. Ramesh,on the machining of

alumina and glass - Manufacture,Volume, September 2002, pages269
1276.
Page 34 of 34

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The Institution of Engineers (India)_ Project Report

DESIGN AND FABRICATION OF

OF ABASIVE JET MACHINE

WINTER 2015(Mechanical Engineering)

Under the esteem guidance of

Mr. Surendara Kumar Thawait(FIE),

The Institution of Engineers (India)

Total Marks - 100

Project Guide - Mr. Surendra Kumar Thawait

Membership No. - F-016816-1

1. Title of the project 8

I hereby declare that myself Gadadhar dey , a senior Technician

(Mr . Surendra Kumar Thawait)

Gadadhar Dey (ST 635979-0) Mechanical Engineering

I am proud to acknowledge the technical direction/guidance provided by

I must also acknowledge the technical support offered by

I also acknowledge the assistance rendered by my seniors and technicians

1.TITLE OF THE PROJECT :

2 .OBJECTIVE OF THE PROJECT :

Abrasive Jet Machining (AJM) is the process of material removal from a

3.RATIONALE OF THE PROJECT :

In this project, a model of the Abrasive Jet Machine is designed

4.METHEDOLOGY TO BE USED FOR CARRYING OUT THE

The methodology comprises of following:

A. Collection of data regarding abrasive particles .

5.EXPECTED CONTRIBUTION FOM THE STUDY:

The outcome of the study is to suggest methods of improving material

6.LIST OF ACTIVITIES TO BE CARRIED OUT TO COMPLETE THE

A. Collection of Sub-Critical Data.

B.Collection of Super-Critical Data.

C. Modification of the process to improve the quality of material

7.PLACE/EQUIPMENTS REQUIRED & PLANNING OF

Location of the project

8.PROBLEM ENVISAGED IN CARRYING OUT THE PROJECT:

A. The abrasive material may accumulate at nozzle and fail the

Gadadhar Dey Mr. Surendra Kumar Thawait

1.TITLE OF THE PROJECT :

NAME OF THE STUDENT : Gadadhar Dey

MEMBERSHIP NO. : ST-635979-0

NAME OF THE PROJECT GUIDE: Surendra Kumar Thawait

MEMBERSHIP NO. : F-016816-1

Gadadhar Dey (ST 635979-0) Mechanical Engineering

S/N. TITLE PAGE NO.

Gadadhar Dey (ST 635979-0) Mechanical Engineering

8.8 Literature Review 19

Gadadhar Dey (ST 635979-0) Mechanical Engineering

3.LIST OF TABLES AND FIGURES:

Gadadhar Dey (ST 635979-0) Mechanical Engineering

Gadadhar Dey (ST 635979-0) Mechanical Engineering

fabricated components rather than directly procuring them, because, the

Gadadhar Dey (ST 635979-0) Mechanical Engineering

8.2 EQUIPMENTS: A schematic layout of AJM is shown in Fig1.

The filtered gas, supplied under pressure to the mixing chamber

Gadadhar Dey (ST 635979-0) Mechanical Engineering

flow and pressure.The nozzle is mounted on a fixture. Either the work

Gadadhar Dey (ST 635979-0) Mechanical Engineering

The major components are:

8.3 DIFFERENT VARIABLES IN ABRASIVE JET MACHINE:

Gadadhar Dey (ST 635979-0) Mechanical Engineering

8.4 CHARECTERSTICS OF DIFFERERNT VARIABLES:

Table 1 Characteristics of different variables

Gadadhar Dey (ST 635979-0) Mechanical Engineering

Gadadhar Dey (ST 635979-0) Mechanical Engineering