DESIGN AND FABRICATION OF ABRASIVE JET MACHINE

A THESIS SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF

Bachelor of Technology In Mechanical Engineering

KRUSHNA PRASAD PRADHAN Roll 10503048

Department of Mechanical Engineering National Institute of Technology Rourkela 2009

DESIGN AND FABRICATION OF ABRASIVE JET MACHINE

A THESIS SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF Bachelor of Technology In Mechanical Engineering

By
KRUSHNA PRASAD PRADHAN Roll 10503048

Under the guidance of Dr. C. K. BISWAS

Department of Mechanical Engineering National Institute of Technology Rourkela 2009

National Institute of Technology Rourkela

CERTIFICATE

This is to certify that the thesis entitled DESIGN AND FABRICATION OF ABRASIVE JET MACHINE Submitted by MR. KRUSHNA PRASAD PRADHAN in partial fulfillment of the requirements for the award of Bachelor of technology Degree in Mechanical Engineering at the National Institute of Technology, Rourkela (Deemed University) is an authentic work carried out by him under my supervision and guidance. To the best of my knowledge, the matter embodied in the thesis has not been submitted to any other University / Institute for the award of any Degree or Diploma.
DATE: Dr. C. K. BISWAS

NATIONALINSTITUTEOFTECHNOLOGY ROURKELA,769008

ACKNOWLEDGEMENT
IdeemitaprivilegetohavebeenastudentofMechanicalEngineeringstreeminNational InstituteofTechnology,Rourkela.Itakethisopportunitytoexpressmygratitudetoallthose who motivated, encouraged and helped me in the project work. Im grateful to my supervisor,Prof.C.K.Biswas,forhiskindsupport,guidanceandencouragementthroughout theprojectwork,alsoforintroducingtomethistopic,whichhasbeenveryinterestingand hasgivenusgreatinsighttothefutureworkonthisarea.Wewouldliketotakethechance toexpressourappreciationtoourfamilymembers.Theircontinuousloveandsupportgave usthestrengthforpursuingourdream.Specialthankstoourfriendsandothermembersof thedepartmentforbeingsosupportiveandhelpfulineverypossibleway. NITRourkela May11,2009 KrushnaPrasadPradhan RollNo10503048

DepartmentofMechanicalEngineering NationalInstituteofTechnology,Rourkela

CONTENTS
TITLE PARTONE 1. Introduction 2. Equipment 3. VariablesinAbrasiveJetMachine 4. CharacteristicsofdifferentVariables 5. Advantages 6. Disadvantages 7. Application: PARTTWO 1. Literaturesurvey: PARTTHREE 1. DESIGNOFCOMPONENTS 1. XYTable: 2. BallScrew: 3. LMGuideorLinearMotionGuideWay: 4. SupportUnit: 5. NutBracket: PAGENO. 4 5 5 7 7 8 8 9 10 11 17 18 18 22 25 30 31

1|P a g e

2. ZAxisAssemblyorVerticalMotionModule: 1. LMguideway: 2. BallScrew&SupportUnit 3. Nozzle 4. LimitationsofAbrasiveJetnozzles: 3. TOTALASSEMBLY 4. OtherComponents i. FRLunit

32 33 34 35 37 38 42 42 43 44 45 46 47 48 49 49 50 51 52

ii. Vibratingunit a. Abrasivecontainer b. Cam 5. CostEstimation PARTFOUR 1. Nozzle 2. Cam 3. Abrasivecontainer 4. Vibratingassembly CONCLUSION

BIBLIOGRAPHY&REFERENCES

2|P a g e

ABSTRACT
AbrasiveJetMachining(AJM)istheprocessofmaterialremovalfromaworkpiecebythe applicationofahighspeedstreamofabrasiveparticlescarriedinagasmediumfroma nozzle.Thematerialremovalprocessismainlybyerosion.TheAJMwillchieflybeusedto cutshapesinhardandbrittlematerialslikeglass,ceramicsetc.themachinewillbe automatedtohave3axestravel.ThedifferentcomponentsofAJMareHorizontalmotion module(XYTable),Verticalmotionmodule(Zmotion),Vibrator,dehumidifier,Pressure Regulator,andDustfilteretc.Thedifferentcomponentsareselectedafterappropriate designcalculations. Inthisproject,amodeloftheAbrasiveJetMachineisdesignedusingCADpackageslike AutoCAD,CATIAetctakingintoconsiderationofcommerciallyavailablecomponents.Care hasbeentakentouselessfabricatedcomponentsratherthandirectlyprocuringthem, because,thelackofaccuracyinfabricatedcomponentswouldleadtoadiminished performanceofthemachine.

3|P a g e

Part

One

INTRODUCTION

4|P a g e

1.1Introduction
AbrasiveJetMachining(AJM)istheremovalofmaterialfromaworkpiecebytheapplication ofahighspeedstreamofabrasiveparticlescarriedingasmediumfromanozzle.TheAJM processdiffersfromconventionalsandblastinginthattheabrasiveismuchfinerandthe processparametersandcuttingactionarecarefullycontrolled. Theprocessisusedchieflytocutintricateshapesinhardandbrittlematerialswhichare sensitivetoheatandhaveatendencytochipeasily.Theprocessisalsousedfordeburring andcleaningoperations.AJMisinherentlyfreefromchatterandvibrationproblems.The cuttingactioniscoolbecausethecarriergasservesasacoolant.

1.2Equipment
AschematiclayoutofAJMisshowninFig1.Thefilteredgas,suppliedunderpressuretothe mixingchambercontainingtheabrasivepowderandvibratingat50c/s,entrainsthe abrasiveparticleandisthepassedintoaconnectinghose.Thisabrasiveandgasmixture emergesfromasmallnozzleathighvelocity.Theabrasivepowderfeedrateiscontrolledby theamplitudeofvibrationofthemixingchamber.Apressureregulatorcontrolsthegasflow andpressure. Thenozzleismountedonafixture.Eithertheworkpieceorthenozzleismovedbycams pantographorothersuitablemechanismstocontrolthesizeandshapeofthecut.Hand operationissometimesadequatetoremovesurfacecontaminationsorincuttingwhere accuracyisnotverycritical.Dustremovalequipmentisnecessarytoprotectthe environment.Commercialbenchmountedunitsincludingallcontrols,motionproducing devices,anddustcontrolequipmentareavailable.
5|P a g e

FIG1:SCHEMATICLAYOUTOFABRASIVEJETMACHINE Themajorcomponentsare: 1. Aircompressor. 2. Airfilter. 3. Dehumidifier. 4. PressureGauge. 5. PressureRegulator. 6. VibratororMixer. 7. Nozzle. 8. HorizontalandVerticalmotionmodule(forxyzmotion). 9. Arrangementtoholdtheworkpiece.

6|P a g e

1.3VariablesinAbrasiveJetMachine:
Thevariablesthatinfluencetherateofmetalremovalandaccuracyofmachininginthis processis: 1. Carriergas 2. Typesofabrasive 3. Sizeofabrasivegrain 4. Velocityofabrasivejet 5. Flowrateofabrasive 6. Workmaterial 7. Geometry,compositionandmaterialofnozzle 8. Nozzleworkdistance(standoffdistance)
9. Shapeofcutandoperationtype

1.3.1CharacteristicsofdifferentVariables:

Medium Abrasive Flowrateofabrasive Velocity Pressure Nozzlesize Materialofnozzle Nozzlelife

Air,CO2,N2 SiC,Al2O3(ofsize20to50) 3to20gram/min 150to300m/min 2to8kg/cm2 0.07to0.40mm WC,Sapphire 12to300hr

7|P a g e

Standoffdistance Workmaterial

0.25to15mm(8mmgenerally) NonMetalslikeglass,ceramics,andgranites. Metalsandalloysofhardmaterialslike germanium,siliconetc

partapplication

Drilling,cutting,deburring,cleaning
TABLE1

1.4Advantages:
1. Abilitytocutintricateholesshapeinmaterialsofanyhardnessandbrittleness. 2. Abilitytocutfragileandheatsensitivematerialwithoutdamage. 3. Nochangeinmicrostructureasnoheatisgeneratedintheprocess. 4. Lowcapitalcost.

1.5Disadvantages:
1. Materialremovalrateislowandhenceitsapplicationislimited. 2. Straystringscanoccurandhenceitsapplicationislimited. 3. Embeddingoftheabrasiveintheworkpiecesurfacemayoccurwhilemachiningsofter material. 4. Theabrasivematerialmayaccumulateatnozzleandfailtheprocessifmoistureispresentin theair. 5. Itcannotbeusedtodrillblindholes.

8|P a g e

1.6Application:
ThemajorfieldofapplicationofAJMprocessisinthemachiningofessentiallybrittlematerialsand heatsensitivematerialslikeglass,quartz,sapphire,semiconductormaterials,micaandceramics.Itis alsousedincuttingslot,thinsections,countering,drilling,deburring,forproducingintegrateshapes inhardandbrittlematerials.ItisoftenusedforcleaningandpolishingofplasticsnylonandTeflon components.Delicatecleaning,suchasremovalofsmudgesfromantiquedocuments,isalso possiblewithAJM. 9|P a g e

PART TWO

LITERATURE SURVEY

10|P a g e

2.1Literaturesurvey:

TheliteraturestudyofAbrasiveJetMachinerevealsthattheMachiningprocesswas startedafewdecadesago.Tilldatetherehasbeenathroughanddetailedexperimentand theoreticalstudyontheprocess.Mostofthestudiesargueoverthehydrodynamic characteristicsofabrasivejets,henceascertainingtheinfluenceofalloperationalvariables ontheprocesseffectivenessincludingabrasivetype,sizeandconcentration,impactspeed andangleofimpingement.Otherpapersfoundnewproblemsconcerningcarriergas typologies,nozzleshape,sizeandwear,jetvelocityandpressure,standoffdistance(SOD), ornozzletipdistance(NTD).Thesepapersexpresstheoverallprocessperformanceinterms ofmaterialremovalrate,geometricaltolerancesandsurfacefinishingofworkpieces,as wellasintermsofnozzlewearrate.Finally,thereareseveralsignificantandimportant paperswhichfocusoneitherleadingprocessmechanismsinmachiningofbothductileand brittlematerials,oronthedevelopmentofsystematicexperimentalstatisticalapproaches andartificialneuralnetworkstopredicttherelationshipbetweenthesettingsof operationalvariablesandthemachiningrateandaccuracyinsurfacefinishing.
(Ref17)

Computationalfluiddynamics(CFD)simulationoftheformationanddischarge

processofanairwaterflowinanabrasivewaterjet(AWJ)headispresentedbyUmberto Prisco&MariaCarminaD'Onofrio.Numericalsimulationshavebeenconductedusingthe commercialcodeFluent6.3byAnsys.DynamiccharacteristicsoftheflowinsidetheAWJ headanddownstreamfromthenozzlehasbeensimulatedundersteadystate,turbulent, twophaseflowconditions.Thefinalaimistogainfundamentalknowledgeoftheultrahigh velocityflowdynamicfeaturesthatcouldaffectthequalityofthejet,suchasthevelocity andpressuredistributionsindifferentpartsoftheAWJheadandattheoutlet.

11|P a g e

(Ref20)

Experimentshavebeenperformedoneffectofjetpressure,abrasiveflowrate

andworkfeedrateonsmoothnessofthesurfaceproducedbyabrasivewaterjetmachining ofcarbideofgradeP25.CarbideofgradeP25isveryhardandcannotbemachinedby conventionaltechniques.Theabrasiveusedininvestigationswasgarnetofmeshsize80.It wastriedtocutcarbidewithlowandmediumlevelofabrasiveflowrate,butthejetfailed tocutcarbidesinceitistoohardandveryhighlevelofenergyisrequired.Minimumrateof abrasiveflowthatmadeitpossibletocutcarbideefficientlywas135gmin1.Withincrease injetpressurethesurfacebecomessmootherduetohigherkineticenergyoftheabrasives. Butthesurfacenearthejetentranceissmootherandthesurfacegraduallybecomes rougherdownwardsandistheroughestnearthejetexit.Increaseinabrasiveflowratealso makesthesurfacesmootherwhichisduetotheavailabilityofhighernumberofcutting edgesperunitareaperunittime.Feedratedidntshowsignificantinfluenceonthe machinedsurface,butitwasfoundthatthesurfaceroughnessincreasesdrasticallynearthe jetentrance. Thestudyoftheresultsofmachiningundervariousconditionsapprovesthata commercialAJMmachinewasused,withnozzlesofdiameterrangingfrom0.45to0.65mm, thenozzlematerialsbeingeithertungstencarbideorsapphire,bothofwhichhavehightool lives.Siliconcarbideandaluminumoxidewerethetwoabrasivesused.Otherparameters studiedwerenozzletipdistances(510mm),sprayangles(60and90)andpressures(5 and7bars)formaterialslikeglass,ceramics,andelectrodischargemachined(EDM)die steel.TheholesdrilledbyAJMmaynotbecircularandcylindricalbutalmostellipticaland

12|P a g e

bellmouthed.Highmaterialremovalrateconditionsdonotnecessarilyyieldsmallnarrow cleancutmachinedareas.
(Ref16)

StudiesrevealthatAJMisanattractivemicromachiningmethodforceramic

materials.ThemachinabilityduringtheAJMprocesscanbecomparedtothatgivenbythe establishedmodelsofsolidparticleerosion,inwhichthematerialremovalisassumedto originateintheidealcrackformationsystem.However,itwasclarifiedthattheerosion modelsarenotnecessarilyapplicabletotheAJMtestresults,becausetherelativehardness oftheabrasiveagainstthetargetmaterial,whichisnottakenintoaccountinthemodels,is criticalinthemicromachiningprocess.NostrengthdegradationtookplacefortheAJM ceramicsurfaces.Thisisattributedtothefactthatradialcracksdidnotpropagate downwardsbyparticleimpactsduringthemachiningprocess.

(Ref14)

AbrasiveWaterJet(AWJ)turningisatechnologythatstilltriestofinditsniche

fieldofapplicationwhereitcanbeeconomicallyviable.ButaparticularapplicationofAWJ turninghasproveditstechnologicalandeconomicalcapability,i.e.profilinganddressingof grindingwheels.Startingfromthetheoreticalconsiderations,thekeyoperatingparameters ofAWJturningareidentifiedandincludedinamethodologytogeneratevariousprofilesof grindingwheelsbymeansoftangentialmovementofthejetplume.Roughinginsinglepass toconcave/convexgeometries(experimenteddepthofcuts<30mm),generationofthin walls/slots(thickness<2mm,depth>430mm)andintricateprofile(e.g.successionoftight radii)onavarietyofgrindingwheelsshowthecapabilityofAWJturningtofulfillthe requirementsofthisnicheapplication.

Themachiningprocessproducesnoheatandhencechangesinmicrostructureor strengthofthesurfaceisunlikely.TheairactsasacoolantandhenceAJMprocesshasa
13|P a g e

highpotentialasdamagefreemicromachiningmethod.Thefracturetoughnessand hardnessofthetargetmaterialsarecriticalparametersaffectingthematerialremovalrate inAJM.However,theirinfluenceonthemachinabilityvariedgreatlywiththeemployed abrasives.

Inrecentyearsabrasivejetmachininghasbeengainingincreasingacceptabilityfor deburringapplications.Theinfluenceofabrasivejetdeburringprocessparametersisnot knownclearly.AJMdeburringhastheadvantageovermanualdeburringmethodthat generatesedgeradiusautomatically.Thisincreasesthequalityofthedeburred components.Theprocessofremovalofburrandthegenerationofaconvexedgewere foundtovaryasafunctionoftheparametersjetheightandimpingementangle,withafixed SOD.Theinfluenceofotherparameters,viz.nozzlepressure,mixingratioandabrasivesize areinsignificant.TheSODwasfoundtobethemostinfluentialfactoronthesizeofthe radiusgeneratedattheedges.Thesizeoftheedgeradiusgeneratedwasfoundtobe limitedtotheburrrootthickness.
(Ref15)

Abrasivejetfinishingcombinedwithgrindinggivesrisetoaprecisionfinishing

processcalledtheintegrationmanufacturingtechnology,inwhichslurryofabrasiveand liquidsolventisinjectedtogrindingzonebetweengrindingwheelandworksurfaceunder noradialfeedcondition.Theabrasiveparticlesaredrivenandenergizedbytherotating grindingwheelandliquidhydrodynamicpressureandincreasedslurryspeedbetween grindingwheelandworksurfaceachievesmicroremovalfinishing.

Abrasivewaterjetmachinesarebecomingmorewidelyusedinmechanical machining.Thesemachinesoffergreatadvantagesinmachiningcomplexgeometricalparts

14|P a g e

inalmostanymaterial.Thisabilitytomachinehardtomachinematerials,combinedwith advancementsinboththehardwareandsoftwareusedinwaterjetmachining,hascaused thetechnologytospreadandbecomemorewidelyusedinindustry.Newdevelopmentsin highpressurepumpsprovidemorehydraulicpoweratthecuttinghead,significantly increasingthecuttingperformanceofthemachine.Analysisoftheeconomicandtechnical hasbeendonebyresearchers.Thosetechnologyadvancementsinapplyinghigherpower machiningandintelligentsoftwarecontrolhaveproventosignificantlyimprovetheoverall performanceoftheabrasivewaterjetmachiningoperation,thuswideningthescopeof possibleapplicationsofthisinnovativeandpromisingtechnology.

(Ref21)

Qualityofthesurfaceproducedduringabrasivewaterjetmachiningof

aluminumhasbeeninvestigatedinrecentyears.Thetypeofabrasiveusedwasgarnetof meshsize80.Thecuttingvariableswerestandoffdistanceofthenozzlefromthework surface,workfeedrateandjetpressure.Theevaluatingcriteriaofthesurfaceproduced werewidthofcut,taperofthecutslotandworksurfaceroughness.Itwasfoundthatin ordertominimizethewidthofcut;thenozzleshouldbeplacedclosetotheworksurface. Increaseinjetpressureresultsinwideningofthecutslotbothatthetopandatexitofthe jetfromthework.However,thewidthofcutatthebottom(exit)wasalwaysfoundtobe largerthanthatatthetop(atastandoffdistanceof3mmandtheworkfeedrateof15mm min1).Itwasfoundthatthetaperofcutgraduallyreduceswithincreaseinstandoff distanceandwasclosetozeroatthestandoffdistanceof4mm(atajetpressureof30ksi andaworkfeedrateof15mmmin1).Thefeedrateoftheworkshouldbekeptwithin40 mmmin1(atthejetpressureof30ksiandthestandoffdistanceof3mm),becauseafeed ratebeyond40mmmin1resultsinsharpincreaseintaperangle.Thejetpressuredoesnot

15|P a g e

showsignificantinfluenceonthetaperanglewithintherangeofworkfeedandthestand offdistanceconsidered.Bothstandoffdistanceandtheworkfeedrateshowstrong influenceontheroughnessofthemachinedsurface.Hencestandoffdistanceshouldbe keptwithin3mm(atajetpressureof30ksiandaworkfeedrateof15mmmin1)andthe workfeedrateshouldbekeptwithin30mmmin1(atajetpressureof30ksiandastand offdistanceof3mm)inordertohaveagoodsurfacefinish,sincebeyondthosevaluesof theparameterstheroughnessofthemachinedsurfacerisessharply.Increaseinjetpressure showspositiveeffectintermsofsmoothnessofthemachinedsurface.Withincreaseinjet pressure,thesurfaceroughnessdecreases(atastandoffdistanceof3mmandworkfeedof 15mmmin1).Thisisduetofragmentationoftheabrasiveparticlesintosmallersizesata higherpressureandduetothefactthatsmallerparticlesproducesmoothersurface.So withinthejetpressureconsidered,theworksurfaceissmoothernearthetopsurfaceand graduallyitbecomesrougherathigherdepths.

16|P a g e

Part

Three

DESIGNOFCOMPONENTS

17|P a g e

3.1DESIGNOFCOMPONENTS 3.1.1XYTable:
XYtableisthemostimportantpartoftheAJMoverwhichtheworkpiecehastobekeptand machined.ThetravelofXYtablehasbeendecidedtobe400x350mm. ThedifferentcomponentsoftheXYtableare: 1. LMguideway(2pairs4nos.) 2. Ballscrew(2nos.) 3. Supportunit(2fixed&2supported) 4. Nutbracket(2nos.) 5. Couplings(2nos.) 6. Standardnutsandbolts. 7. Othercomponents(tobemanufacturedinthelab). TheXYtableconsistsoftwoparts:(a)Uppertable,(b)Lowertable.Theuppertableisresponsible forxmovementandhasatravelof400mm.Thelowertablehasatravelof350mmandis responsiblefortheymotionoftheworkpiece. Thedifferentdiagramsoftheassembledviewsalongwithdimensionshavebeenshownbelow.

18|P a g e

FIG2:XYTABLEASSEMBLY(ISOMETRICVIEW)

19|P a g e

 FIG3:XYTABLEASSEMBLY(2DVIEWS)

20|P a g e

 FIG4:XYTABLE(TOPVIEW)

FIG5:XYTABLE(SIDEVIEW) 21|P a g e

3.1.2BallScrew:
Ballscrewissimilartoleadscrewsuperficiallybutthefrictionisgreatlyreducedincaseofball screwsbyinsertingrecirculatingballsinbetweenthescrewthreadandthenut.Thethreadprofileis madecircularandthenutthreadhasgotareverseshapewhichformsaspiralcavityinsidewhichthe ballsmovewhenthenutisrotated.Oncetheballsreachtheendofthenuttheyareagain recirculatedbymeansofareturnpipe.Ballscrewscanpreloadedornonpreloaded.Theaccuracy increasesincaseofpreloadedtypeofballscrewastwosetsofballsarepressedtowardeachother therebymakingtheradialclearanceclosetozero.

FIG6:RECIRCULATINGBALLSCREW

22|P a g e

Screwlengthcalculation: TravelofXYtablehasbeendecidedtobe400x350mm. Soscrewofxaxisballscrew: = 400mm + 200mm+ 100mm

(Travel) = 700mm.

(Uppertablebreadth)

(Allowanceforbellowscover)

Screwlengthyaxisballscrew: = 350mm (Travel) = 650mm. + 200mm + 100mm

(Upperarrangement)

(Bellowscoverallowance)

CommercialBallscrewsareavailablefromcompanieslike(1)THK,(2)GrampusImpexLtd.,(3) PrecisionBearingHouse,and(4)ABBAetc. Thespecificationsbycompaniesthatsatisfyourrequirementare: BNF20055RRG2850L700C7 BNF 20 05 RR G2 modelno. screwshaftdiameter lead labyrinthsealattached axialclearancegrade overallshaftlength(inmm) screwlength accuracysymbol 23|P a g e (byTHKCompany)

850L 700 C7

SFI2005C7800650P0 SFI 20 05 C7 800 650 P0 modelno.(Singlenut) screwshaftdiameter lead accuracygrade totallength screwlength precisionlevel

FIG7:SCREWTHREAD

24|P a g e

FIG8:BALLSCREWASSEMBLY(SHOWINGDIMESIONSANDMACHINEDENDS)

3.1.3LMGuideorLinearMotionGuideWay:
LMGuideasthenamesuggestsisusedforhighlypreciselinearmotion.Itcansustainhighloadsin anydirectionandhencecanbemountedinanydirection.Theassemblycontainsarailwhichguides ablockonit.Insidetheblock,ballorrollerarepresentwhichdrasticallyreducesthefrictionallosses. SoLMGuideispreferredinbothindustriesandroboticstoachievespecificfunctions.

FIG9:LMGUIDEASSEMBLY

25|P a g e

StructureandFeatures:
BallsrollinfourrowsofracewaysprecisiongroundonanLMrailandanLMblock,andendplates incorporatedintheLMblockallowtheballstocirculate.Sinceretainerplatesholdtheballs,theydo notfalloffeveniftheLMrailispulledout(exceptmodelsHSR8,10and12).Eachrowofballsis placedatacontactangleof45sothattheratedloadsappliedtotheLMblockareuniforminthe fourdirections(radial,reverseradialandlateraldirections),enablingtheLMGuidetobeusedinall orientations.Inaddition,theLMblockcanreceiveawellbalancedpreload,increasingtherigidityin the four directions while maintaining a constant, low friction coefficient. With the low sectional heightandthehighrigiditydesignoftheLMblock,thismodelachieveshighlyaccurateandstable linearmotion. 4wayequalload

FIG10:LOADONLMBLOCK Eachrowofballsisplacedatacontactangleof45sothattheratedloadsappliedtotheLMblock are uniform in the four directions (radial, reverseradial and lateral directions), enabling the LM Guidetobeusedinallorientationsandinextensiveapplications Highrigiditytype Sinceballsarearrangedinfourrowsinawellbalancedmanner,alargepreloadcanbeappliedand therigidityinfourdirectionscaneasilybeincreased

26|P a g e

Highdurability Even under a preload or biased load, differential slip of balls does not occur. As a result, smooth motion,highwearresistance,andlongtermmaintenanceofaccuracyareachieved.

RatedLoadsinAllDirections
ModelHSRiscapableofreceivingloadsinallfourdirections:radial,reverseradialandlateral directions.Thebasicloadratingsareuniforminthefourdirections(radial,reverseradialandlateral directions),andtheiractualvaluesareprovidedinthedimensionaltableforHSR.

EquivalentLoad

When the LM block of model HSR receives loads in the reverseradial and lateral directions simultaneously,theequivalentloadisobtainedfromtheequationbelow

PEPRPLPT Where PE Equivalentload Radialdirection Reverseradialdirection Lateraldirection PR Radialload (N) (N)

27|P a g e

PL Reverseradialload PT Lateralload

(N) (N)

AdvantageofLMGuide 1. Smoothmovementwithnoclearance. 2. Highrunningprecisionwithease. 3. Highrigidityinalldirection. 4. Highpermissibleloadrating. 5. Highlongtermprecision. 6. Highspeedoperation. Thesecombinetogiverise 1. Lowtotalcost. 2. HighprecisioninmachinesincorporatingtheLMguide. 3. Highproductivityinthesame. 4. Substantialenergysaving. 5. Highefficiencyinmachinedesign. 6. Simplemaintenance.

28|P a g e

Raillengthcalculation: Lengthofrailshouldbeapproximately50mmlargerthanthatofcorrespondingballscrew. HenceinXaxis:raillength=750mm. Yaxis:raillength=700mm.

LMGuidesarecommerciallyavailablefromcompanieslike(1)THK,(2)GrampusImpexLtd.,(3) PrecisionBearingHouse,and(4)ABBAetc. Thespecificationbycompaniesthatsatisfyourrequirementis: HSR30R2SSC5700LHII HSR 30R 2 SS C5 modelno. sizespecification 2blocksperrail endseal+sideseal radialclearance standardlength accuracygrade 2rails

700L H II

29|P a g e

FIG11:DIMENSIONSOFLMGUIDE

3.1.4SupportUnit:

FIG12:SUPPORTUNIT Supportunitsarerequiredforsupportingtheballscrewends.Thesearespecialkindofbearings whichgiveslongerservicelifeandbetterperformance.Theyareof2types, 1. Fixedendsupportunit, 2. Supportedendsupportunit. Infixedendthesupportunitactslikeathrustbearingandtakesallthethrustgivenbythework load.Inthesupportedendthesupportunitjustactslikesimplebearing. 30|P a g e

Varioustypesofsupportedunitsareavailablecommercially.Theydiffermainlyinthemannerthey needtobefixedorboltedtoawallorametalplate.Accordinglythefixingholesareprovidedonthe faceorsidesofthesupportunit. SupportunitsavailablecommerciallybyTHKaretypeEKforfixedsideandFKforsupportedside.

FIG13:SUPPORTUNIT(DESIGNEF)

3.1.5NutBracket:
Nutbracketisusedtobolttheballscrewnutwiththeworkloadplatform.Followingdiagramshows anutbracketalongwithaballscrewnut.

FIG14:NUTBTACKET

31|P a g e

3.2ZAxisAssemblyorVerticalMotionModule:
Verticalmotionmoduleisrequiredforadjustingthenozzleheightorstandoffdistancefromthe workpiece.Whendifferentoperationsaretobecarriedout,thesetuptimebetweenoperationscan beeliminatedifthenozzletipisraisedtoaheightmorethan5cm.Atthisdistancetheabrasivejet hasnegligibleerosioneffectontheworkpiece.HencethetotalZmotionhasbeendecidedtobe 100mm. ThedifferentcomponentsoftheVerticalmotionmoduleare: 1. LMguideway(1no.) 2. Ballscrew(1no.) 3. Supportunit(1fixed&1supported) 4. Couplings(1no.) 5. Nozzle(1no.) 6. Standardnutsandbolts. 7. Othercomponents(tobemanufacturedinthelab). Theassemblyviewisshowninthenextpage.

32|P a g e

Supportunit

Pipeholder

Ball screw LMGuide

Nozzleholder

Nozzle

Supportunit

FIG15:VERTICALMOTIONMODULE

3.2.1LMguideway:
TheLMGuideselectedisofthetypeHSRYR.ThespecialfeatureofHSRYRisthatthetappedholes arepresentonthesideoftheLMBlockandhencetheycanbeattachedtotheloadcomponentfrom theside.

33|P a g e

FIG16:LMGuide(typeHSRYR)

3.2.2BallScrew&SupportUnit
TheballscrewselectedfortheZaxisassemblyisofthetypeBNT.ThesupportunitsareEKandFK forfixedendandsupportedendrespectively.ThesmallerspaceintheZassemblydoesntallowfor theuseofanutbracketfortheballscrewnut.SotheBNTtypeballscrewhasbeenselectedfrom THKcatalogueasithastappedholesonthenutitselfwhichcanbescrewedtotheloaddirectly.

FIG17:BALLSCREWANDSUPPORTUNIT

34|P a g e

3.2.3Nozzle:
Theabrasiveparticlesaredirectedintotheworksurfaceathighvelocitythroughnozzles.Therefore, thematerialofthenozzleissubjectedtogreatdegreeofabrasionwearandhencethesearemade ofhardmaterialssuchastungstencarbideorsyntheticsapphire.Tungstencarbidenozzlesareused forcircularcrosssectionsintherangeof0.120.8mmdiameter,forrectangularsectionsofsize0.08 x0.05to0.18x3.8mmandforsquaresectionsofsizeupto0.7mm.Sapphirenozzlesaremadeonly forcircularcrosssections.Thesizevariesfrom0.2to0.7mmdiameter.Nozzlesaremadewithan externaltapertominimizesecondaryeffectsduetoricochetingofabrasiveparticles.Nozzlesmade oftungstencarbidehaveanaveragelifeof12to30hourswhilenozzlesofsapphirelastforabout 300hourofoperationwhenusedwith27mabrasivepowder. Therateofmaterialremovalandthesizeofmachinedareaareinfluencedbythedistanceofthe nozzlefromtheworkpiece.Theabrasiveparticlesfromthenozzlefollowaparallelpathonlyfora shortdistanceandthenthejetflaresresultingintheoversizingofthehole.Itisobservedthatthejet streamisinitiallyacylinderforabout1.6mmandthenitflaresintoaconeof7includedangle.The materialremovalrateinitialincreaseswithincreaseinthedistanceofthenozzlefromtheworkpiece becauseoftheaccelerationofparticlesleavingnozzle.Thisincreaseismaximumuptoadistance about8mmandthenitsteadilydropsoffbecauseofincreaseinmachiningareaforthesame amountofabrasiveanddecreaseinvelocityofabrasivestreamduetodrag.

35|P a g e

FIG18:NOZZLE Workpiece
Standoff distance

Nozzletip

FIG19:Abrasiveactionofparticles

36|P a g e

3.2.4LimitationsofAbrasiveJetnozzles:
Despitetheirsimpledesign,abrasivejetnozzlescanbetroublesomeattimes.Therearemanydesigns,but theysharethesameproblems:

1. Shortlifeofanexpensivewearpart 2. Occasionalpluggingofmixingtube:Usuallycausedbydirtorlargeparticlesinabrasive. 3. Wear,misalignment,anddamagetothejewel.

37|P a g e

3.3TOTALASSEMBLY
Theassemblydrawingoftheabrasivejetmachinecanberepresentedasfollows.Itcanbenoted thatthecomponentslikeaircompressor,vibrator,dehumidifier,bellowscoverandpipinghavenot beenshowninthedrawing

FIG20:SIDEVIEWOFWHOLEASSEMBLY

38|P a g e

FIG21:AJMFRONTVIEW

39|P a g e

 FIG22:AJMTOPVIEW

40|P a g e

 FIG23:AJMISOMETRICVIEW

41|P a g e

3.4OtherComponents
3.4.1FRLUnit(Dehumidifier):
TheFRLUnit(AirFilterRegulatorLubricatorunit)whichisotherwisecalledthemoistureseparatoror dehumidifierisrequiredforseparatingthemoisturefromair.Atmosphericairalwayscontainssome watervapourinit.Astheairwithhighvelocityisblownfromthenozzlethereisanabruptrisein pressurewhichconvertswatervapourintomoisture.Themoisturemakestheabrasiveparticlesto agglomerateandthisclogstheoutletoftheNozzle.Toavoidthiscloggingmoistureseparatorshould beusedbeforeabrasiveparticlesaremixedwithcompressedair.DifferentFRLUnitsareavailable commercially.

Outlet

Inlet

CirculationofAir

Chemicals forseparatingmoisture

FIG24:FRLUnit

42|P a g e

3.4.2TheVibratingUnit:
VibratingUnitisusedformixingtheairwiththeabrasiveparticles(Al2O3).TheAbrasive particlesarestoredinacontainerthroughwhichairisflown.Theparticlesareagitatedby meansofacamandmotorarrangement.Therotationofcamresultsinvibrationinthe abrasivecontainer.Theflowrateofabrasivematerialscanbecontrolledbymanipulating therotationalspeedofthemotor.Theabrasivecontainerwillhaveoneinletandoneoutlet forairpassageandwillbeverticallysuspendedfromahingedjoint. SotheVibratingUnitconsistsoffollowingparts 1. Motor(Inductiontype) 2. Cam 3. Abrasivecontainer

43|P a g e

AbrasiveContainer:

FIG25:TheAbrasiveContainer.

44|P a g e

Cam:
Camisfixedwithshaftoftheinductionmotor.Theprofileofthecamistakentobeacircular one.Thedistancebetweentwocentersasshowninfig26is3mm.Whenthemotorrotates;it makesthecontainertovibrate.Widthofcamis25mm.

FIG26:Cam

45|P a g e

3.3.5ApproximateCostEstimation:
TABLE:2(Costestimation)
SLNO. NAMEOFTHEITEM COSTPERSINGLE NO.OFITEMS PIECE 1 Recirculatingballscrew Xaxis Yaxis Zaxis 2 LinearMotionguideways Xaxis Yaxis Zaxis 3 SupportUnit Xaxisballscrew Yaxisballscrew Zaxisballscrew 4 5 6 FRLUnit Vice Angles Rs.10,000.00 Rs.7,000.00 Rs.5,000.00 Rs.17,000.00 Rs.14,000.00 Rs.6,000.00 Rs.3,000.00 Rs.2,500.00 Rs.2,500.00 Rs.2,500.00 Rs.2,000.00 Rs.1000.00 REQUIRED 1 1 1 1pair 1pair 1 2 2 2 1 Rs.2500.00 Rs.2,000.00 Rs.1000.00 Rs.16,000.00 TOTALCOST FORTHEITEM Rs.22,00.00 Rs.37,000.00

Otheraccessories TOTAL

Rs.7,500.00 Rs.88,000.00

46|P a g e

Part

Four

FABRICATION AND ASEMBLING

47|P a g e

4.1Nozzle:
A standard MS cylindrical rod was cut into required length by power hacksaw. The external diameterwasthenbroughtto16mmbyturningitinlatheandthenthetipwasmadebytapering oneendbythesamelathe.Ablindholeofapproximatedepth20mmwasmadeontheplannerface oftherodbymeansofa12mmdrillbitinadrillingmachine.Theendoftheblindholeformsashape of118degreetaperbecauseofthetooltipangle.Internalthreadingwasmadeby12mmtap.Then the tip of the nozzle was made by drilling it by a 0.74mm diameter drill bit to get approximate diameterof1mm.

FIG27:Nozzle

48|P a g e

4.2CAM:
Mildsteelofdiameter40mmwastakenasrawmaterialforthisoperation.Atfirstturningwasdone inalathetobringdownthediameterto35mm.Thentherequiredwidth(25mm)wascutbypower hacksawandboththecutfacesweremachinedinamillingmachine.Thenathroughholewasmade bya16mmdrillbitinadrillingmachine.Thecenteroffsetwastakentobe3mm.

4.3ABRASIVECONTAINER:
Theabrasivecontainerwasmadeoutofahollowcylinder.Twoironplateswereweldedonboth endsofthecontainer.Onthetopplatetwoholesweredrilledandironpipeswerefittedwiththese holes.Theinletironpipeislongersoastomakemoreagitationoftheabrasiveparticles.Theoutlet pipeisshorter.Boththepipesareclampedwithnylonpipeswhichcarriesairthroughthem.After removalofmoisturebytheFRLunitthecompressedairgoestoabrasivecontainerthroughinlet, mixeswithabrasiveparticleandthentheairwithabrasiveparticlesmovesthroughthenozzleto performthemachiningaction.

49|P a g e

4.5THEVIBRATORASSEMBLY:
Theanglesectionwasweldedwithbaseplatebyarcwelding.Arodwasweldedwithangleorienting itparallelwithbaseplate.Aninductionmotorwasplacedonthebaseplatebytightenwithnutbolt. Camwasfixedwithmotorshaft.Thenabrasivecontainerwasconnectedtotherodbymeansofthe holder.Thecontainerisfreetorotatearoundtherod.

FIG28:Thevibratorassembly

50|P a g e

CONCLUSION
InthisprojectacompletedesignoftheAbrasiveJetMachineisgiven.TheXYZmotion modulesaredesignedtakinginaccountofcurrentlyavailablecomponentsinthemarket. Thedesigningandassemblingofverylargenumberofcomponentswasatremendoustask andwascompletedontime.Howeverbecauseofsomepartscouldntbepurchasedthe wholeassemblywaslimitedtodrillingoperation. Theprojectcangobeyonditscurrentpositionandcapabilitiesbyemployingautomation intoit.ThiscanbedonebyusingsteppermotorsorDCservomotorsinterfacedwith standardPCIcontrollersorstandalonecontrollers.2Dprofilescanbeconvertedinto standardGcodesandMcodesandthatcanbesenttothemachinetoperformautomated machining.

51|P a g e

Bibliography&References
BOOKS

1. Productiontechnology,HMTpublication. 2. Elementsofworkshoptechnology,SKHajraChoudhury,SKBose,AKHajra choudhury,NiranjanRoy,VolII,Mediapromotersandmediapublications 3. Modernmachiningprocess,SPandeyandHNShah,S.Chandandco.

WEBSITES

4. www.scopus.com 5. www.sciencedirect.com. 6. www.maharashtradirectory.com 7. www.grampusimpex.com 8. www.thk.co.in 9. www.apex.com 10. www.elgi.com 11. www.indiamart.com
JOURNALS

12. Residualstressandtribologicalcharacteristicsofgroundsurfaceafterabrasivejet restrictedbygrindingwheel Authors:Liu,F.,Gong,Y.D.,Shan,Y.Q.,Cai,G.Q. Publication:JournalofNortheasternUniversity,Volume30,Issue3,Pages422425 March2009. 13. Simulationandanalysisofabrasivejetmachiningwithwheelrestrictioningrinding Authors:Wang,W.S.,Zhu,L.D.,Yu,T.B.,Yang,J.Y.,Tang,L. Publication:KeyEngineeringMaterials,Volume389390,Pages387391, 2009
52|P a g e

14. AbrasivewaterjetturningAnefficientmethodtoprofileanddressgrindingwheels Authors:D.A.Axinte,J.P.Stepanian,M.C.Kong,J.McGourlay

Publication:InternationalJournalofMachineToolsandManufacture,Volume49, Issues34,March2009,Pages351356

Date:Dec,2008 15. Modelingandsimulationformaterialremovalinabrasivejetprecisionfinishingwith wheelasrestraint. Authors:Li,C.H.,Ding,Y.C.,Lu,B.H. Publication:ProceedingsoftheIEEEInternationalConferenceonAutomationand Logistics,ICAL2008,Articlenumber4636666,Pages28692873,2008 16. Abrasivejetmicromachiningofplanarareasandtransitionalslopes Authors:Ghobeity,A.;Spelt,J.K.;Papini,M. Publication:JournalofMicromechanicsandMicroengineering,Volume18,Issue5, pp.055014. PublicationDate:01/05/2008 17. ThreeDimensionalCFDSimulationofTwoPhaseFlowInsidetheAbrasiveWaterJet CuttingHead Authors:UmbertoPrisco;MariaCarminaD'Onofrio. Publication:InternationalJournalofComputationalMethodsinEngineeringScience
andMechanics9(5),pp.300319

PublicationDate:01September2008 18. Machinabilityofglassbyabrasivewaterjet Authors:Zhu,H.T.,Huang,C.Z.,Wang,J.,Lu,X.Y.andFeng,Y.X. Publication:InternationalJournalofMaterialsandProductTechnology,Vol.31, No.1,pp.106112,2008.

53|P a g e

19. Surfaceevolutionmodelsforabrasivejetmicromachiningofholesinglassand polymethylmethacrylate(PMMA) Authors:Ghobeity,A.;Getu,H.;Papini,M.;Spelt,J.K. Publication:JournalofMicromechanicsandMicroengineering,Volume17,Issue11, pp.21752185(2007). Date:11/2007 20. SurfaceRoughnessofCarbidesProducedbyAbrasiveWaterJetMachining Authors:Khan,AhsanAli;Awang,MohdEfendeeBin;Annuar,AhmadAzwariBin Publication:JournalofAppliedScience,vol.5,Issue10,p.17571761 Date:06/2005 21. AStudyonAbrasiveWaterJetMachiningofAluminumwithGarnetAbrasives. Authors:Khan,AhsanAli;Munajat,NoraziatyBt.;Tajudin,HarnisahBt. Publication:JournalofAppliedScience,vol.5,Issue9,p.16501654 Date:01/2005 22. Effectofworkpiecepropertiesonmachinabilityinabrasivejetmachiningofceramic materials Authors:M.Wakuda,Y.YamauchiandS.Kanzaki Publication:PrecisionEngineering,Volume26,Issue2,April2002,Pages193198 23. Anexperimentalstudyontheabrasivejetdeburringofcrossdrilledholes Authors:R.Balasubramaniam,J.KrishnanandN.Ramakrishnan Publication:JournalofMaterialsProcessingTechnology,Volume91,Issues13,30
June1999,Pages178182

24. Astudyontheshapeofthesurfacegeneratedbyabrasivejetmachining Authors:R.Balasubramaniam,J.KrishnanandN.Ramakrishnan Publication:JournalofMaterialsProcessingTechnology,Volume121,Issue1,14

February2002,Pages102106

54|P a g e

25. Abrasivejetmachiningofglassatlowtemperature Authors:M.K.MujuandA.K.Pathak Publication:JournalofMechanicalWorkingTechnology,Volume17,August1988,

Pages325332

26. Anexperimentalstudyofabrasivejetmachining Authors:A.P.VermaandG.K.Lal Publication:InternationalJournalofMachineToolDesignandResearch,Volume24,

Issue1,1984,Pages1929

55|P a g e