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Introduction
It is one of the un conventional process
which depends on the concept of
mechanical erosion.
In this process a fine grained abrasives are
thrown over the work piece at a very high
speed. Generally used jet consists of
abrasives mixed with air (or) some other
carrier gases at high pressure.
In this process the material is removed by
the erosion caused due to the jet.
1) Carrier gas
The carrier gas should not excessively in to
the atmosphere. The gas should have some
properties like
a. Non-toxic
b. Easily available
c. Cheap
d. Drying and cleaning should not be difficult
Some of the most commonly used carrier
gases are air, carbon dioxide, nitrogen. Of all
air is most commonly used carrier gas. As its
properties satisfies the requirements of
carrier gas while using air Air filters should
be strictly employed.
2) Type of abrasive
Abrasives are selected according to type of
machining operation to be employed. The
abrasives should be having sharp and irregular
shapes and should be fine enough to get
suspended in the carrier gas. It should also have
excellent flow properties. Some of the most
commonly and frequently used abrasives for
cutting are
a. Aluminum carbide
b. Silicon carbide
And that for cleaning, etching, deburring and
polishing are silicon bicarbonate, dolomite, glass
beads etc. It is not recommended to re use the
abrasives which are already used as they may
affect the flow rate and cutting rate. In some
cases they tries to clog the nozzle.
3) Grain size
The rate of material removal rate is high and if it is
small then the cutting is small. If the small grain size is
used then they may stick together and there is a
possibility for chocking of nozzle. In general grains of
size ranging from 10 micron to 50 micron are used.
Coarse and fine grains are used for cutting where as
fine grains are used for polishing and deburring etc.
4) Standoff distance
It is the effective distance between the nozzle tip and
the work piece. It has a considerable affect on the rate
of material removal. If a small standoff distance is
maintained there is every chance of the penetration of
abrasive particles in to the work piece. If lager
standoff distance is maintained flaring may take place.
It is found from various experiments that the effective
standoff distance is 0.8mm
7) Work material
Abrasive jet machining is generally used for
machining brittle materials like glass, ceramics etc.
The effective metal removal rate highly depends on
the hardness of work piece material. Ductile materials
are partially unmachinable by abrasive jet machining.
8) Nozzle design
Nozzle has to withstand various conditions like
erosive action of abrasive materials, pressure and
kinetic energy of jet. The most commonly used
materials for nozzle are sapphire, tungsten carbide.
Pressure losses at the end of nozzle should be very
low. Depending on the requirements the nozzle may
be designed either in rectangular or circular cross
sections
9) Shape of cut
Accuracy of machining may also be
dependent on the shape of cut. It is
not possible to machine the sharp
edges as there is a problem of micro
cracks.
nozzle
workpiece
MRR
MRR
Mixing ratio
MRR
Gas pressure
MRR