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Abrasive jet machining (AJM) is commonly used for Cutting, Cleaning, Drilling and Etching operation
Mechanism of AJM
Fine particles are accelerated in gas stream .
The particles are directed towards the focus of machining. As the particle impacts the surface, it causes a small fracture, and the gas stream carries both the abrasive particles and the fractured (wear) particles away.
Compressor
Constructional Details
Equipments involved in the construction of the Abrasive Jet Machine are as follows
Process Parameters
The variables that influence the rate of metal removal are as follows :
1.Carrier Gas :
Carbon dioxide, nitrogen & air. Air is most widely used
2.Abrasive :
Aluminum oxide, Silicon carbide, Sodium bicarbonate etc.
3.Velocity of abrasive :
The jet velocity is a function of nozzle pressure & design. The range of jet velocity is 150-300 m/min
4. Work Material :
It is recommended for processing of brittle material
1 2 3 4
Hopper
Compressor
Regulating Valve
Mixing Chamber
Nozzle
Workpiece Table
Experimental Procedure:
Glass was used as a test specimen, was cut into square and rectangular shape for machining on AJM. Specimens were cleaned using air jet and weighed on a sensitive scale, accurate to 0.001 gram . Each test sample was placed on the work chamber and machined by abrasive jet machine by varying various process parameters The machine work piece was then removed, cleaned and weighed again to determine the amount of material removed from the work piece. The size of hole at the top surface and bottom surface was measured and the results were tabulated.
Experimental Details:
Experiment No:1- NTD Vs Diameter of Hole
Observation 1.1
1
NTD=6
2
NTD=12
3
NTD=15
4
NTD=18
Thickness of material = 4 mm
Observation Table
Pressure = 5.5 Kgf/cm2 S.No. 1 2 3 4 Nozzle Tip Distance NTD (mm) 6 12 15 18 Top Surface Dia (mm) 7.05 8.72 11.21 11.65 Bottom Surface Dia (mm) 4.51 5.05 5.33 6.65
Graph
12 11 10
NTD (mm)
9 8 7 6 5 4 6 8 10 12 14 16 18
NTD (mm)
Fig 1.1.2. Shows the graph of Diameter of Hole vs. Nozzle Tip Distance
Fig 1.2.1 Machined Work piece at Pressure =6.5 kgf/cm2 Thickness of material = 4 mm
Observation Table
Pressure = 6.5 Kgf/cm2 S.No. 1 2 3 4 Nozzle Tip Distance NTD (mm) 6 12 15 18 Top Surface Dia mm 7.55 9.75 11.15 11.75 Bottom Surface Dia mm 4.55 5.65 5.91 6.05
Graph
Top Surface Dia. Bottom Surface Dia.
12 11 10
NTD (mm)
9 8 7 6 5 4 6 8 10 12 14 16 18
NTD (mm)
Observation Table
Pressure = 8 Kgf/cm2 S.No. 1 2 3 4 Nozzle Tip Distance NTD (mm) 6 12 15 18 Top Surface Dia mm 7.72 9.95 11.45 11.81 Bottom Surface Dia mm 5.05 5.75 5.96 6.75
Graph
12 11 10
NTD (mm)
9 8 7 6 5 6 8 10 12 14 16 18
Fig 2.1.2 Machined work piece for determination of MRR at Pr.=6.5 kgf/cm2 Pressure 6.5 kgf/cm2 Initial weight = 141.200 gm Final Weight = 141.130 gm Time = 20 sec Thickness = 8mm MRR = 210 mg/min
Fig.2.1.3 Machined work piece for determination of MRR at Pr.=7.5 kgf/cm2 Pressure 7.5 kgf/cm2 Initial weight = 137.530 gm Final Weight = 137.370 gm Time = 20 sec Thickness = 8mm MRR = 400 mg/min
Observation Table
Thickness = 8 mm, NTD = 12 mm S.No. Pressure kgf/cm2 Initial Weight (gm) Final Weight (gm) Time (sec) MRR (mg/min)
1 2
3
5.5 6.5
7.5
140.190 141.200
137.530
140.150 161.130
137.370
20 20
20
120 210
400
Graph
400
350
300
MRR (mg/min)
250
200
150
7.5
Pressure (Kgf/cm )
Fig. 2.2.1 Machined work piece for determination of MRR at Pr.=5.5 kgf/cm2 Pressure 5.5 kgf/cm2 Initial weight = 206.600gm Weight = 206.570 gm Time = 20 sec Thickness = 12 mm MRR = 90 mg/min
Fig.2.2.2 Machined work piece for determination of MRR at Pr.=6.5 kgf/cm2 Pressure 6.5 kgf/cm2 Initial weight = 207.130gm Final Weight = 207.059 gm Time = 20 sec Thickness = 12mm MRR = 213 mg/min
Fig 2.2.3 Machined work piece for determination of MRR at Pr.=7.5 kgf/cm2 Pressure 7.5 kgf/cm2 Initial weight = 201.750 gm Final Weight = 201.590 gm Time = 20 sec Thickness = 12mm MRR = 480mg/min
Observation Table
Thickness = 12 mm, NTD = 12 mm S.No. Pressure kgf/cm2 5.5 6.5 7.5 Initial Weight (gm) 206.600 207.130 201.750 Final Weight (gm) 206.570 207.059 201.590 Time (sec) 20 20 20 MRR (mg/min) 90 213 480
1 2 3
Graph
550 500 450 400
MRR mg/min
350 300 250 200 150 100 50 5.5 6.0 6.5 7.0
2
7.5
Pressure Kgf/cm
Conclusion:
Abrasive Jet Machine was fabricated with following specification: 1. 2. 3. 4. Diameter of nozzle = 3 mm Type of abrasive particle aluminum oxide (AlO2) Pressure range 5 to 8 kgf/cm2 Carrier gas used Dry air
References
M. Roopa Rani and S. Seshan Abrasive Jet Machining-Process Variables and Current ApplicationMetals Materials and Process,1995 Vol.7 No.4,pp 279 -290. P K Ray and Dr A K Paul, Some Studies on Abrasive Jet Machining Journal of the Institution of Engineers (India) vol 68 part PE 2 November 1987 Alok K.Verma, Cheng Y. Lin Associate Professor ,Engineering Technology Dept. Old Dominion University Norfolk, Virginia Parametric Study of the Efficacy of Cutting Process in Abrasive Jet Machining (AJM)
P. C. Pandey & H.S. Shan , Modern Machining Tata McGraw-Hill Publishing Company , Edition :1980
Production Technology HMT Tata McGraw-Hill Publishing Company , Edition :1980 Maleev & Hartman Machine Design edited by O. P. Grover CBS Publishing & Distributor
Amitabh Ghosh & Ashok Kumar Malik Manufacturing Process East West Press Private Limited ,New Delhi, Edition 1995
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