Abrasive jet machining

Presented by
Name : ARKO MAJUMDER
Roll no. : 06/ME/58
Branch : MECHANICAL ENGINEERING
Semester : 7th
University roll no. : 10307061077
University regd. No. : 103010711051
 INTRODUCTION
Machining process is the technique by which products can be made with proper
shape, size and accuracy according to human needs. In nature, materials are available
in different shape and sizes, called blanks. Desired shapes are produced by removing
the layers of excess material from the blank or raw material.
In practice, machining process is defined into two broad categories:-
1. Traditional machining
2. Non-traditional machining

Traditional machining can be done either by removing layers of material in form

of chips or by continuous erosion in form of granules. Usually in Lathe, Milling and
Shaping machines material is removed in form of chips by a wedge shaped device
called cutting tool. In case of material removal in form of granules, usually Grinding,
Lapping and Honing process is used.
Usually Lathe, Milling, Shaping process is used for rough machining and rapid
removal of material. On the other hand, Grinding, Lapping, Honing process is used
for finish machining by slowly removing the material.

Non-traditional machining is done on the principle of removing material by sp-

ecial method e.g. by chemical reaction, heating and vaporizing or mechanical process.
Chemical process uses electrolytic reaction to remove material. In heating method,
heating is usually done by laser, ion beam, plasma. In mechanical process machining
is done by abrasive particles.

Advantages of traditional machining :-

 easy to maintain or handle the process. Highly skilled labour is not needed.
 material removal is rapid. Shapes are obtained very quickly. It means high
MRR can be obtained.

Disadvantages of traditional machining :-

 cutting tool must be made of harder material more than work piece.
 tremendous heat is generated at tool-work interface for which structure of tool
or work piece may change.
 high accuracy can’t be obtained by this methods.
 For the drawbacks of traditional or conventional machining, non-conventional
or non-traditional machining is introduced. There are various types of machining
processes are available in this method. Such a process, named as ABRASIVE JET
MACHINING (AJM), is involved in non-traditional machining.

Abrasive jet machining

It is a non-traditional process in which abrasive particles are used to remove the
material. Here the extra material is removed by brittle fracture due to high impact of
abrasive particles.

Diagram of ABRASIVE JET MACHINING

A focussed stream of abrasive particles and high pressure gas or air is made
to impinge on work piece through a nozzle. The work material is removed by means
of erosion of the work material due to brittle fracture because of high impact of abra-
sive particles.
In this process very fine particles in order of microns are mixed with gas which
helps in cutting.
 PROCESS :-
1. Carrier gas is compressed in compressor at a pressure around 5 bar.
2. The carrier gas must be dry enough. For this it is passed through drier to make
this fully dried.
3. The gas is passed through filters to separate the impurities like dust (in air).
4. After that the gas is passed through pressure regulator to obtain the desired pre-
ssure.
5. Then the gas is sent to mixing chamber to mix with abrasive particles.

Schematic diagram of ABRASIVE JET MACHINING

6. Abrasive particles are loaded to mixing chamber through a hopper.

7. At the bottom of the hopper, a sieve is present which has a very minute opening.
It allows only small particles to mix up with gas.
8. An electromagnetic shaker or vibrator is used to shake the sieve and small parti-
cles come out to mix with gas.
9. After mixing chamber a control valve is present to regulate the flow rate of gas
and abrasive mixture.
10. Then the mixture is passed through a nozzle and impinged on the work piece in
form of jet.
 PROCESS PARAMETERS :-

1. ABRASIVE PARTICLES : Abrasive particles used in AJM have irregular sha-

pes. These are very fine in nature. Usually the size of abrasive particles is 0.025 mm
or 25 microns. The size of particles usually vary from 10 to 50 microns with the kind
of operation performed. Usually aluminum oxide (Al 2O3), Silicon carbide (SiC),
Sodium Bicarbonate (NaHCO3), Glass bead are used as abrasive particles.

2. CARRIER GAS : In AJM usually air, CO2,N2 are used as carrier gas. They
are almost inert in nature and are readily available. The pressure is maintained at 2-
8.5 Kgf/cm² and flow rate is usually maintained at 5-30 lit/min. These gases are kept
at a very high pressure and passed through very thin aperture so that it can strike job
face at a very high velocity.

3. STAND-OFF DISTANCE : The distance between the nozzle and work surface
is called stand-off distance (SOD). The accuracy of machining is very much depend-
ent upon SOD. If the SOD is increased, abrasive particles are impinged on a greater
area. SOD is usually maintained at less than 1mm.
 PROCESS CRITERIA :

1. MATERIAL REMOVAL RATE (MRR): MRR is an important parameter for

machining. In AJM material removal rate depends upon
* abrasive flow rate
* abrasive size
* mixing ratio
* gas pressure
* SOD
MRR gradually increases with increase in flow rate and abrasive size.

50µ
MRR
25µ

10µ

abrasive flow rate

With an increase in mixing ratio MRR at first increases and then decreases.
MRR also increases with increase in gas pressure.

MRR

Mixing ratio

MRR

For different gases

Gas pressure
 As the SOD increases, MRR at first increases and then comes at a constant. If
SOD is further increased, MRR decreases.

MRR

SOD

2. SURFACE FINISH : Very fine surface finish is obtained in this process due to
the strike of very fine particles and slow MRR.

3. VELOCITY : Usually the velocity of jet is maintained at around 200 – 400 m/s.

DESIGN OF NOZZLE :- Nozzle design is very important in AJM. Abrasive

particles flow in a large velocity which strikes work surface as well as inner surface
of nozzle. So nozzle may be eroded. For this it should be made of hard and corrosion
resistant material. Usually nozzles are made of tungsten carbide or sapphire.

this is a figure of a nozzle used in AJM

 WATER-ABRASIVE JET MACHINING : Now a days water is mixed
with abrasive particles instead of gas or air. It is also a convenient process because
water is readily available. It also acts as a coolant for the heat generated at strike
point of abrasives and work surface.
In this case jet velocity is maintained
at 90 m/s. Abrasive particles reduces the
cutting force and enables to cut thick work
piece like 80 mm. Usually corundum,
silicon carbide, quartz sand is used as
abrasive.

ADVANTAGES OF AJM:
1. No heat generation takes place in this process. So it is best suited for ma-
chining brittle and heat sensitive materials.
2. It is used for machining super alloy and refractory material.
3. No tool changing is required in this process.
4. Intricate parts can be machined easily by this process.
5. Material cut by AJM obtains a surface which has smooth, satin like face.
6. Parts produced by this process can be directly used without deburring.
7. Operation is easy and safe. Skilled labour is not needed.

DISADVANTAGES OF AJM:
1. Abrasive particles can’t be recycled.
2. During machining abrasive particles may erode the side of desired shape.
So proper care should be taken at the time of machining.
3. MRR is much lower than conventional process.

APPLICATIONS :
 machining of super alloy and refractory material
 for making intricate hole
 cutting, grooving, finishing of glass, ceramics etc.
 making vinyl, foam covering of car dashboard panel
 making composite body panels of interior cars
 making small bio-medical parts
 CONCLUSION
ABRASIVE JET MACHINING is used rapidly in industries now a
days. Although having some disadvantages, AJM is used because
of its hazard free process. AJM can give a better surface finish and
good machining characteris- tics. It is readily used in precise
machining.