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.

Dr. C. K. BISWAS

DATE:

NATIONALINSTITUTEOFTECHNOLOGY
ROURKELA,769008

ACKNOWLEDGEMENT

IdeemitaprivilegetohavebeenastudentofMechanicalEngineeringstreeminNational
InstituteofTechnology,[Link]
who motivated, encouraged and helped me in the project work. Im grateful to my
supervisor,[Link],forhiskindsupport,guidanceandencouragementthroughout
theprojectwork,alsoforintroducingtomethistopic,whichhasbeenveryinterestingand
[Link]
[Link]
[Link]
thedepartmentforbeingsosupportiveandhelpfulineverypossibleway.

NITRourkela

KrushnaPrasadPradhan

May11,2009

RollNo10503048

DepartmentofMechanicalEngineering
NationalInstituteofTechnology,Rourkela

CONTENTS
TITLE

PAGENO.

PARTONE

1. Introduction

2. Equipment

3. VariablesinAbrasiveJetMachine

4. CharacteristicsofdifferentVariables

5. Advantages

6. Disadvantages

7. Application:

PARTTWO

10

1. Literaturesurvey:
PARTTHREE
1. DESIGNOFCOMPONENTS

11
17
18

1. XYTable:

18

2. BallScrew:

22

3. LMGuideorLinearMotionGuideWay:

25

4. SupportUnit:

30

5. NutBracket:

31

1|P a g e

2. ZAxisAssemblyorVerticalMotionModule:

32

1. LMguideway:

33

2. BallScrew&SupportUnit

34

3. Nozzle

35

4. LimitationsofAbrasiveJetnozzles:

37

3. TOTALASSEMBLY

38

4. OtherComponents

42

i.

FRLunit

ii. Vibratingunit
a. Abrasivecontainer
b. Cam
5. CostEstimation
PARTFOUR

42
43
44
45
46
47

1. Nozzle

48

2. Cam

49

3. Abrasivecontainer

49

4. Vibratingassembly

50

CONCLUSION

51

BIBLIOGRAPHY&REFERENCES

52

2|P a g e

ABSTRACT
AbrasiveJetMachining(AJM)istheprocessofmaterialremovalfromaworkpiecebythe
applicationofahighspeedstreamofabrasiveparticlescarriedinagasmediumfroma
[Link]
cutshapesinhardandbrittlematerialslikeglass,[Link]
[Link]
module(XYTable),Verticalmotionmodule(Zmotion),Vibrator,dehumidifier,Pressure
Regulator,[Link]
designcalculations.
Inthisproject,amodeloftheAbrasiveJetMachineisdesignedusingCADpackageslike
AutoCAD,[Link]
hasbeentakentouselessfabricatedcomponentsratherthandirectlyprocuringthem,
because,thelackofaccuracyinfabricatedcomponentswouldleadtoadiminished
performanceofthemachine.

3|P a g e

Part

One

INTRODUCTION

4|P a g e

1.1Introduction
AbrasiveJetMachining(AJM)istheremovalofmaterialfromaworkpiecebytheapplication
[Link]
processdiffersfromconventionalsandblastinginthattheabrasiveismuchfinerandthe
processparametersandcuttingactionarecarefullycontrolled.
Theprocessisusedchieflytocutintricateshapesinhardandbrittlematerialswhichare
[Link]
[Link]
cuttingactioniscoolbecausethecarriergasservesasacoolant.

1.2Equipment
[Link],suppliedunderpressuretothe
mixingchambercontainingtheabrasivepowderandvibratingat50c/s,entrainsthe
[Link]
[Link]
[Link]
andpressure.
[Link]
[Link]
operationissometimesadequatetoremovesurfacecontaminationsorincuttingwhere
[Link]
[Link],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

Air,CO2,N2

Abrasive

SiC,Al2O3(ofsize20to50)

Flowrateofabrasive

3to20gram/min

Velocity

150to300m/min

Pressure

2to8kg/cm2

Nozzlesize

0.07to0.40mm

Materialofnozzle

WC,Sapphire

Nozzlelife

12to300hr

7|P a g e

Standoffdistance

0.25to15mm(8mmgenerally)

Workmaterial

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,[Link]
alsousedincuttingslot,thinsections,countering,drilling,deburring,forproducingintegrateshapes
[Link]
[Link],suchasremovalofsmudgesfromantiquedocuments,isalso
possiblewithAJM.

9|P a g e

PART TWO

LITERATURE SURVEY

10|P a g e

2.1Literaturesurvey:

TheliteraturestudyofAbrasiveJetMachinerevealsthattheMachiningprocesswas
[Link]
[Link]
characteristicsofabrasivejets,henceascertainingtheinfluenceofalloperationalvariables
ontheprocesseffectivenessincludingabrasivetype,sizeandconcentration,impactspeed
[Link]
typologies,nozzleshape,sizeandwear,jetvelocityandpressure,standoffdistance(SOD),
ornozzletipdistance(NTD).Thesepapersexpresstheoverallprocessperformanceinterms
ofmaterialremovalrate,geometricaltolerancesandsurfacefinishingofworkpieces,as
[Link],thereareseveralsignificantandimportant
paperswhichfocusoneitherleadingprocessmechanismsinmachiningofbothductileand
brittlematerials,oronthedevelopmentofsystematicexperimentalstatisticalapproaches
andartificialneuralnetworkstopredicttherelationshipbetweenthesettingsof
operationalvariablesandthemachiningrateandaccuracyinsurfacefinishing.
(Ref17)

Computationalfluiddynamics(CFD)simulationoftheformationanddischarge

processofanairwaterflowinanabrasivewaterjet(AWJ)headispresentedbyUmberto
Prisco&MariaCarminaD'[Link]
[Link]
headanddownstreamfromthenozzlehasbeensimulatedundersteadystate,turbulent,
[Link]
velocityflowdynamicfeaturesthatcouldaffectthequalityofthejet,suchasthevelocity
andpressuredistributionsindifferentpartsoftheAWJheadandattheoutlet.
11|P a g e

(Ref20)

Experimentshavebeenperformedoneffectofjetpressure,abrasiveflowrate

andworkfeedrateonsmoothnessofthesurfaceproducedbyabrasivewaterjetmachining
ofcarbideofgradeP25.CarbideofgradeP25isveryhardandcannotbemachinedby
[Link]
wastriedtocutcarbidewithlowandmediumlevelofabrasiveflowrate,butthejetfailed
[Link]
[Link]
injetpressurethesurfacebecomessmootherduetohigherkineticenergyoftheabrasives.
Butthesurfacenearthejetentranceissmootherandthesurfacegraduallybecomes
[Link]
makesthesurfacesmootherwhichisduetotheavailabilityofhighernumberofcutting
[Link]
machinedsurface,butitwasfoundthatthesurfaceroughnessincreasesdrasticallynearthe
jetentrance.

Thestudyoftheresultsofmachiningundervariousconditionsapprovesthata
commercialAJMmachinewasused,withnozzlesofdiameterrangingfrom0.45to0.65mm,
thenozzlematerialsbeingeithertungstencarbideorsapphire,bothofwhichhavehightool
[Link]
studiedwerenozzletipdistances(510mm),sprayangles(60and90)andpressures(5
and7bars)formaterialslikeglass,ceramics,andelectrodischargemachined(EDM)die
[Link]

12|P a g e

[Link]
cleancutmachinedareas.
(Ref16)

StudiesrevealthatAJMisanattractivemicromachiningmethodforceramic

[Link]
establishedmodelsofsolidparticleerosion,inwhichthematerialremovalisassumedto
[Link],itwasclarifiedthattheerosion
modelsarenotnecessarilyapplicabletotheAJMtestresults,becausetherelativehardness
oftheabrasiveagainstthetargetmaterial,whichisnottakenintoaccountinthemodels,is
[Link]
[Link]
downwardsbyparticleimpactsduringthemachiningprocess.
(Ref14)

AbrasiveWaterJet(AWJ)turningisatechnologythatstilltriestofinditsniche

[Link]
turninghasproveditstechnologicalandeconomicalcapability,[Link]
[Link],thekeyoperatingparameters
ofAWJturningareidentifiedandincludedinamethodologytogeneratevariousprofilesof
[Link]
toconcave/convexgeometries(experimenteddepthofcuts<30mm),generationofthin
walls/slots(thickness<2mm,depth>430mm)andintricateprofile([Link]
radii)onavarietyofgrindingwheelsshowthecapabilityofAWJturningtofulfillthe
requirementsofthisnicheapplication.

Themachiningprocessproducesnoheatandhencechangesinmicrostructureor
[Link]
13|P a g e

[Link]
hardnessofthetargetmaterialsarecriticalparametersaffectingthematerialremovalrate
[Link],theirinfluenceonthemachinabilityvariedgreatlywiththeemployed
abrasives.

Inrecentyearsabrasivejetmachininghasbeengainingincreasingacceptabilityfor
[Link]
[Link]
[Link]
[Link]
foundtovaryasafunctionoftheparametersjetheightandimpingementangle,withafixed
[Link],[Link],mixingratioandabrasivesize
[Link]
[Link]
limitedtotheburrrootthickness.
(Ref15)

Abrasivejetfinishingcombinedwithgrindinggivesrisetoaprecisionfinishing

processcalledtheintegrationmanufacturingtechnology,inwhichslurryofabrasiveand
liquidsolventisinjectedtogrindingzonebetweengrindingwheelandworksurfaceunder
[Link]
grindingwheelandliquidhydrodynamicpressureandincreasedslurryspeedbetween
grindingwheelandworksurfaceachievesmicroremovalfinishing.

Abrasivewaterjetmachinesarebecomingmorewidelyusedinmechanical
[Link]

14|P a g e

[Link],combinedwith
advancementsinboththehardwareandsoftwareusedinwaterjetmachining,hascaused
[Link]
highpressurepumpsprovidemorehydraulicpoweratthecuttinghead,significantly
[Link]
[Link]
machiningandintelligentsoftwarecontrolhaveproventosignificantlyimprovetheoverall
performanceoftheabrasivewaterjetmachiningoperation,thuswideningthescopeof
possibleapplicationsofthisinnovativeandpromisingtechnology.
(Ref21)

Qualityofthesurfaceproducedduringabrasivewaterjetmachiningof

[Link]
[Link]
surface,[Link]
werewidthofcut,[Link]
ordertominimizethewidthofcut;thenozzleshouldbeplacedclosetotheworksurface.
Increaseinjetpressureresultsinwideningofthecutslotbothatthetopandatexitofthe
[Link],thewidthofcutatthebottom(exit)wasalwaysfoundtobe
largerthanthatatthetop(atastandoffdistanceof3mmandtheworkfeedrateof15mm
min1).Itwasfoundthatthetaperofcutgraduallyreduceswithincreaseinstandoff
distanceandwasclosetozeroatthestandoffdistanceof4mm(atajetpressureof30ksi
andaworkfeedrateof15mmmin1).Thefeedrateoftheworkshouldbekeptwithin40
mmmin1(atthejetpressureof30ksiandthestandoffdistanceof3mm),becauseafeed
[Link]

15|P a g e

showsignificantinfluenceonthetaperanglewithintherangeofworkfeedandthestand
[Link]
[Link]
keptwithin3mm(atajetpressureof30ksiandaworkfeedrateof15mmmin1)andthe
workfeedrateshouldbekeptwithin30mmmin1(atajetpressureof30ksiandastand
offdistanceof3mm)inordertohaveagoodsurfacefinish,sincebeyondthosevaluesof
[Link]
[Link]
pressure,thesurfaceroughnessdecreases(atastandoffdistanceof3mmandworkfeedof
15mmmin1).Thisisduetofragmentationoftheabrasiveparticlesintosmallersizesata
[Link]
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)[Link]
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
[Link]
madecircularandthenutthreadhasgotareverseshapewhichformsaspiralcavityinsidewhichthe
[Link]
[Link]
increasesincaseofpreloadedtypeofballscrewastwosetsofballsarepressedtowardeachother
therebymakingtheradialclearanceclosetozero.

FIG6:RECIRCULATINGBALLSCREW

22|P a g e

Screwlengthcalculation:
TravelofXYtablehasbeendecidedtobe400x350mm.
Soscrewofxaxisballscrew:
=

400mm

(Travel)
=

200mm+

100mm

(Uppertablebreadth)

(Allowanceforbellowscover)

700mm.

Screwlengthyaxisballscrew:

350mm

200mm

(Travel)

(Upperarrangement)

100mm

(Bellowscoverallowance)

650mm.

CommercialBallscrewsareavailablefromcompanieslike(1)THK,(2)GrampusImpexLtd.,(3)
PrecisionBearingHouse,and(4)ABBAetc.

Thespecificationsbycompaniesthatsatisfyourrequirementare:
BNF20055RRG2850L700C7
BNF

modelno.

20

screwshaftdiameter

05

lead

RR

labyrinthsealattached

G2

axialclearancegrade

(byTHKCompany)

850L

overallshaftlength(inmm)

700

screwlength

C7

accuracysymbol
23|P a g e

SFI2005C7800650P0
SFI

modelno.(Singlenut)

20

screwshaftdiameter

05

lead

C7

accuracygrade

800

totallength

650

screwlength

P0

precisionlevel

FIG7:SCREWTHREAD

24|P a g e

FIG8:BALLSCREWASSEMBLY(SHOWINGDIMESIONSANDMACHINEDENDS)

3.1.3LMGuideorLinearMotionGuideWay:
[Link]
[Link]
[Link],ballorrollerarepresentwhichdrasticallyreducesthefrictionallosses.
SoLMGuideispreferredinbothindustriesandroboticstoachievespecificfunctions.

FIG9:LMGUIDEASSEMBLY

25|P a g e

StructureandFeatures:
BallsrollinfourrowsofracewaysprecisiongroundonanLMrailandanLMblock,andendplates
[Link],theydo
notfalloffeveniftheLMrailispulledout(exceptmodelsHSR8,10and12).Eachrowofballsis
placedatacontactangleof45sothattheratedloadsappliedtotheLMblockareuniforminthe
fourdirections(radial,reverseradialandlateraldirections),enablingtheLMGuidetobeusedinall
[Link],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
[Link](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

(N)

Radialdirection

Reverseradialdirection

Lateraldirection

PR Radialload

(N)

27|P a g e

PL Reverseradialload

(N)

PT Lateralload

(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

modelno.

30R

sizespecification

2blocksperrail

SS

endseal+sideseal

C5

radialclearance

700L

standardlength

accuracygrade

II

2rails

29|P a g e

FIG11:DIMENSIONSOFLMGUIDE

3.1.4SupportUnit:

FIG12:SUPPORTUNIT
[Link]
whichgiveslongerservicelifeandbetterperformance.Theyareof2types,
1. Fixedendsupportunit,
2. Supportedendsupportunit.
Infixedendthesupportunitactslikeathrustbearingandtakesallthethrustgivenbythework
[Link].
30|P a g e

[Link]
[Link]
faceorsidesofthesupportunit.
SupportunitsavailablecommerciallybyTHKaretypeEKforfixedsideandFKforsupportedside.

FIG13:SUPPORTUNIT(DESIGNEF)

3.1.5NutBracket:
[Link]
anutbracketalongwithaballscrewnut.

FIG14:NUTBTACKET

31|P a g e

3.2ZAxisAssemblyorVerticalMotionModule:
Verticalmotionmoduleisrequiredforadjustingthenozzleheightorstandoffdistancefromthe
[Link],thesetuptimebetweenoperationscan
[Link]
[Link]
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:
[Link]
arepresentonthesideoftheLMBlockandhencetheycanbeattachedtotheloadcomponentfrom
theside.

33|P a g e

FIG16:LMGuide(typeHSRYR)

3.2.2BallScrew&SupportUnit
[Link]
[Link]
[Link]
THKcatalogueasithastappedholesonthenutitselfwhichcanbescrewedtotheloaddirectly.

FIG17:BALLSCREWANDSUPPORTUNIT

34|P a g e

3.2.3Nozzle:
[Link],
thematerialofthenozzleissubjectedtogreatdegreeofabrasionwearandhencethesearemade
[Link]
forcircularcrosssectionsintherangeof0.120.8mmdiameter,forrectangularsectionsofsize0.08
[Link]
[Link]
[Link]
oftungstencarbidehaveanaveragelifeof12to30hourswhilenozzlesofsapphirelastforabout
300hourofoperationwhenusedwith27mabrasivepowder.
Therateofmaterialremovalandthesizeofmachinedareaareinfluencedbythedistanceofthe
[Link]
[Link]
[Link]
materialremovalrateinitialincreaseswithincreaseinthedistanceofthenozzlefromtheworkpiece
[Link]
about8mmandthenitsteadilydropsoffbecauseofincreaseinmachiningareaforthesame
amountofabrasiveanddecreaseinvelocityofabrasivestreamduetodrag.

35|P a g e

FIG18:NOZZLE

Nozzletip

Standoff
distance

Workpiece

FIG19:Abrasiveactionofparticles

36|P a g e

3.2.4LimitationsofAbrasiveJetnozzles:
Despitetheirsimpledesign,[Link],but
theysharethesameproblems:

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

37|P a g e

3.3TOTALASSEMBLY
[Link]
thatthecomponentslikeaircompressor,vibrator,dehumidifier,bellowscoverandpipinghavenot
beenshowninthedrawing

FIG20:SIDEVIEWOFWHOLEASSEMBLY

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FIG21:AJMFRONTVIEW

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FIG22:AJMTOPVIEW

40|P a g e


FIG23:AJMISOMETRICVIEW

41|P a g e

3.4OtherComponents
3.4.1FRLUnit(Dehumidifier):
TheFRLUnit(AirFilterRegulatorLubricatorunit)whichisotherwisecalledthemoistureseparatoror
[Link]
[Link]
[Link]
[Link]
[Link]
commercially.

Outlet

Inlet

CirculationofAir

Chemicals forseparatingmoisture

FIG24:FRLUnit

42|P a g e

3.4.2TheVibratingUnit:
VibratingUnitisusedformixingtheairwiththeabrasiveparticles(Al2O3).TheAbrasive
[Link]
[Link]
[Link]
[Link]
forairpassageandwillbeverticallysuspendedfromahingedjoint.
SotheVibratingUnitconsistsoffollowingparts
1. Motor(Inductiontype)
2. Cam
3. Abrasivecontainer

43|P a g e

AbrasiveContainer:

FIG25:TheAbrasiveContainer.

44|P a g e

Cam:
[Link]
[Link];it
makesthecontainertovibrate.Widthofcamis25mm.

FIG26:Cam

45|P a g e

3.3.5ApproximateCostEstimation:
TABLE:2(Costestimation)
SLNO.

NAMEOFTHEITEM

COSTPERSINGLE [Link]

Recirculatingballscrew

TOTALCOST

PIECE

REQUIRED

FORTHEITEM

Xaxis

Rs.10,000.00

Yaxis

Rs.7,000.00

Rs.22,00.00

Zaxis

Rs.5,000.00

LinearMotionguideways

Xaxis

Rs.17,000.00

1pair

Yaxis

Rs.14,000.00

1pair

Zaxis

Rs.6,000.00

SupportUnit

Xaxisballscrew

Rs.3,000.00

Yaxisballscrew

Rs.2,500.00

Zaxisballscrew

Rs.2,500.00

FRLUnit

Rs.2,500.00

Rs.2500.00

Vice

Rs.2,000.00

Rs.2,000.00

Angles

Rs.1000.00

Rs.1000.00

Otheraccessories

Rs.7,500.00

TOTAL

Rs.88,000.00

Rs.37,000.00

Rs.16,000.00

46|P a g e

Part

Four

FABRICATION AND ASEMBLING

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

FIG27:Nozzle

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4.2CAM:
[Link]
[Link](25mm)wascutbypower
[Link]
bya16mmdrillbitinadrillingmachine.Thecenteroffsetwastakentobe3mm.

4.3ABRASIVECONTAINER:
[Link]
[Link]
[Link]
[Link]
removalofmoisturebytheFRLunitthecompressedairgoestoabrasivecontainerthroughinlet,
mixeswithabrasiveparticleandthentheairwithabrasiveparticlesmovesthroughthenozzleto
performthemachiningaction.

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4.5THEVIBRATORASSEMBLY:
[Link]
[Link].
[Link]
[Link].

FIG28:Thevibratorassembly

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CONCLUSION
[Link]
modulesaredesignedtakinginaccountofcurrentlyavailablecomponentsinthemarket.
Thedesigningandassemblingofverylargenumberofcomponentswasatremendoustask
[Link]
wholeassemblywaslimitedtodrillingoperation.
Theprojectcangobeyonditscurrentpositionandcapabilitiesbyemployingautomation
[Link]
standardPCIcontrollersorstandalonecontrollers.2Dprofilescanbeconvertedinto
standardGcodesandMcodesandthatcanbesenttothemachinetoperformautomated
machining.

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Bibliography&References
BOOKS

1. Productiontechnology,HMTpublication.
2. Elementsofworkshoptechnology,SKHajraChoudhury,SKBose,AKHajra
choudhury,NiranjanRoy,VolII,Mediapromotersandmediapublications
3. Modernmachiningprocess,SPandeyandHNShah,[Link].

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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

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14. AbrasivewaterjetturningAnefficientmethodtoprofileanddressgrindingwheels
Authors:[Link],[Link],[Link],[Link]
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,[Link],Y.X.
Publication:InternationalJournalofMaterialsandProductTechnology,Vol.31,
No.1,pp.106112,2008.

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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:[Link],[Link]
Publication:PrecisionEngineering,Volume26,Issue2,April2002,Pages193198
23. Anexperimentalstudyontheabrasivejetdeburringofcrossdrilledholes
Authors:[Link],[Link]
Publication:JournalofMaterialsProcessingTechnology,Volume91,Issues13,30
June1999,Pages178182

24. Astudyontheshapeofthesurfacegeneratedbyabrasivejetmachining
Authors:[Link],[Link]
Publication:JournalofMaterialsProcessingTechnology,Volume121,Issue1,14
February2002,Pages102106

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25. Abrasivejetmachiningofglassatlowtemperature
Authors:[Link]
Publication:JournalofMechanicalWorkingTechnology,Volume17,August1988,
Pages325332

26. Anexperimentalstudyofabrasivejetmachining
Authors:[Link]
Publication:InternationalJournalofMachineToolDesignandResearch,Volume24,
Issue1,1984,Pages1929

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