PROJECT REPORT ON

PREDICTION OF MRR IN MICRO ABRASIVE

JET MACHINING BY SEMI-EMPIRICAL MODEL
BY: SHUBHANSHU NEEKHRA
Roll no. 13104045
Enroll. No. GGV/13/1284
Contact no. 08989458055
B.Tech 4th year (Mechanical Engg.)
Institute of Technology
Guru Ghasidas Vishwavidyalaya, Bilaspur

Under the Guidance of:

Dr. Somashekhar S.Hiremath
(Asso.professor)
Mechanical Engineering Department
Indian Institute of Technology
Madras

Place of Work
Indian institute of technology
Madras

Submitted on:
12 July, 2016

Mentor sign.

Introduction:
Abrasive jet machining (AJM) is a material removal process, in which
microscopic abrasive particles are accelerated in a compressed carrier
gas, and fed through a nozzle to produce a jet of high velocity particles.

The impact of the particle jet on target results in material removal, due to
mechanical process such as cutting, ploughing and fracture. Various types
of eroded micro features, such as micro-channels, micro-holes and
stepped planar areas can be created on the target surface by controlling
the jet trajectory, transverse speed, and through the use of an erosive
resistant mask. AJM has recently used to machine a variety of microcomponents, including microfluidic chips, flat panel displays, inertial
sensors, and other high aspect features for micro electro-mechanical
(MEMS) components in glass as well as ceramic materials.

Fig.1. Principle of abrasive jet machining

H.Z.Li et al.[1] done theoretical analysis for finding particle velocity in micro
abrasive jet machining (MAJM) considering it depends up on the nozzle

length, particle mean diameter, particle density, air density, and air flow
velocity of the velocity distribution in AJM. While common parameters that
depends on erosion rate are air pressure, abrasive mass flow rate, standoff distance, and machining time (for hole machining) ,or transverse
speed (for channel machining) taking which J.M.Fan et al.[2] predicted the
mathematical models for the erosion rate in hole and channel machining
on glass by MAJM using a dimensional analysis technique. A theoretical
analysis was done by A. P. Verma et al.[3] to find out the abrasive particle
velocity. A. Nouhi et al.[4] presents a surface evolutions models for
predicting channel profiles of machined surface in both brittle and ductile
material by using AJM. While T. Burzynski et al.[5] carried out surface
evolution prediction of inclined masked micro-channels in glass and PMMA

by implementation of narrow band level set methods (LSM) .H. Getu et al.
[6], [7] and S. Ally et al.[8]also deal with erosion rate using masked and
unmasked micro-channels machined in PMMA at a variety of impact
angles. N. Shafiei et al.[9] develops a computer simulation for predicting
the shape and size of the erosion profile sand Huan Qi et al.[10] does
computational model using discrete element method to numerically
calculate the impact erosion. A. Ghobeity et al.[8] predicts the cross
section profiles for masked and unmasked channels. The cost of abrasives
contributes significantly to the cleaning cost so the recycling of abrasives
makes this process more environment friendly, more economical and
more sustainable. The rate of material removal is one of the most
important quantities for the machining process. To explore the uses of
MAJM for different industrial purposes it is necessary to increase the
material removal rate. In this paper, the empirical model for the prediction
of MRR in micro holes on soda lime glasses are developed using
dimensional technique. The predictive model established as a function of
the particle projectile parameters and target material properties. Then the
models are finally assessed by analysing the model prediction and by
comparing with the experimental data.
NOMENCLATURE:K, K 1 , K 2 , K 3 ,

SYMBO
LS
i
dp

a, b, u, v, l, m, x, y are constants

DIMENSION
FORMULA
M 0 L1 T 0

Depth of indentation (mm)

Particle diameter (mm)

M 0 L1 T 0

Radius of hemispherical crater (mm)

M L T

vr

3
Volume of material removed ( mm )

M 0 L3 T 0

mp

Mass of abrasive particle (g)

M 1 L0 T 0

Density of the abrasive particle (g/

mm3 )

M 1 L3 T 0

Stress on work material (N/ mm

ma

Mass flow rate (g/min)

M L T

rp

Radius of the abrasive particle(mm)

M L T

Target material youngs modulus (GPa)

M L T

M L T

Hardness of target material (GPa)

M L T

vp

Velocity of the particle (m/sec)

M 0 L1 T 1

Air pressure (MPa)

M 1 L1 T 2

Stand of distance (mm)

M 0 L1 T 0

Machining time (min)

M L T

Table-1
**How we get dimensional formula of each term.
Base quantities and their dimensions:Sr.
no.
1
2
3
4
5
6
7

Quantity name

SI unit

Length ,width , depth ,

height

Metre

Time
Mass
Temperature
Amount of substance
Electric current
Luminous intensity

Dimension
symbol
L

Second
Kilogram
Kelvin
Mole
Ampere
Candela
Table-1

Lets take c (i . e . stress) , and find its dimension formula

We know

force
area

mass acceleration
area

Now, writing SI units of all the terms on right hand side (RHS)
So we get
c

Kg

m
s2

m2

Now using table (1) put the dimensional symbol of each term
i.e.

M
=

L2

L
T2

ML T 2
2
L

M L T

T
M

N
I
J

 c is given by

So dimension formula for

M 1 L1 T 2

Similarly, we can find the dimensional formula for any physical quantity. In
the nomenclature section dimension formula for the terms are given which
are used in this model.
ASSUMPTIONS:1.
2.
3.
4.
5.

Particle is of spherical shape.

Flow rate is assumed to be fixed for model.
Machining time is taken as 1 min.
The volume of the material removed is in hemispherical shape.
The total kinetic energy of the particle is converted in to the
workdone to remove material.

Abrasive Particle

c
2r

Work Material

Fig.2
From fig.1, In ABC,
dp
dp
i , BC=r
,
AC=
2
2

AB=

Using Pythagoras theorem,

AB2

AC 2

dp
2

dp
2

( )

dp
i
2

dp
i
2

( )

r2 =

d p . i

BC 2

2
+ r

i2

r2

(Here, the target material is glass i.e. brittle material. And in brittle
material the depth of indentation will not be more than 5-6% of its total
height .In this case total height is d p whose two values are .045 and .07
mm. So 5% of the maximum value (i.e.0.07mm) is 0.0035mm. So our
value is 0.0035 from this we can find the value of

=0.00001225

which is very less and can be neglected)

So,
r

d p . i ..(1)

Volume of the material removed = volume of the hemispherical

crater
vr

2
3

3
r

vr

2
3

3/ 2
(d p . i )
.. (2)

1
2
Kinetic energy of the particle = 2 m p v p

3
1 4 dp

p v p2
2 3
2

( ( ) )

1 3
d p p v p2
2 6

(3)

From this eqn. we can say that K.E = f ( d p , p , v p .

Work done =

2 c

1
2 force deflection

force
area
2
r i

, force= c area
2
force= c r
c=

1
= 2 c (d p . i ) i ... (4) [ r= d p . i ]

Considering total kinetic energy is converted in to work done.

K.E = Work done
1 3
d p p v p2
2 6

(d p i ) i
2 c

Solving this equation we get

p
= v p . d p 6 c (5)

removed number of impacts

[ byvolume
]
a single particle ] [
per minute

Material removal rate =

MRR

MRR

MRR

mass flow rate of abrasive

mass of abrasive particle

vr

2
3

(d p . i )3/ 2

ma

(d p)3
6

... (6)

4. i3 /2 .ma

Putting the value of

MRR

from eqn. (5) in eqn. (6)

1.04 .

.... (7)

Here, stress on the work piece material ( c ) depends upon particle and
impacting parameters v p , m p , r p ( i.e. velocity, mass, radius) of the

abrasive particle as well as on the target material properties E, H (i.e.

Youngs modulus and the hardness of the target material).
Thus

is a function of v p , p , r p , E, H

i.e.
c = ( v p , p , r p , E, H)
By using dimensional analysis technique
** {WHAT IS DIMENSIONAL ANALYSIS?
Dimensional analysis is a means of simplifying a physical problem by
appealing to dimensional homogeneity to reduce the number of relevant
variables.
There are 2 methods which can be used for dimensional analysis.
1. Rayleigh method
2. Buckingham -theorem.
Generally, Rayleigh method is used when the no. of variables are
less (up to 4)and as the no. of variables increase then this process
becomes complex and lengthy. In such circumstances Buckingham
-theorem is used which can be used for large no. of variables.
Steps involved in Buckingham -theorem.
(1) If a problem involves n relevant variables m independent
dimensions then it can be reduced to a relationship between n m
non-dimensional parameters 1, ..., n-m.
(2) To construct these non-dimensional groups: (i) Choose m
dimensionally-distinct repeating variables. (ii) For each of the n m
remaining variables construct a non-dimensional of the form
a
b
c
= (variable). (R .V )1 . ( R .V )2 . (R .V )3 .
Where R.V denotes repeating variable and a, b, c, ... are chosen so as to
make each non-dimensional. }
Here, we use Buckingham -theorem as:
No. of variables = 6
Physical dimensions are mass, length, time =3
So,
No. of -terms will be = (6-3) =3
So there will be 3 repeating variables
i.e.

1. Radius of particle ( r p )
2. Velocity of the particle ( v p )

3. Density of the particle ( p )

{**Note. In order to ensure dimensional independence in {MLT} systems
it is common but not obligatory to choose the repeating variables as: a
purely geometric quantity (e.g. a length), a kinematic (time- but not
mass-containing) quantity (e.g. velocity or acceleration) and a dynamic
(mass- or force-containing) quantity (e.g. density). }

r p a v pb pc c

By putting dimension formula of each term,

M 0 L0 T 0
0

M L T

=
=

La . Lb T b . M c L3 c . M 1 L1 T 2
M

c+1

a +b3 c1

b2

On comparing the powers of M, L& T respectively on both the sides

We get
For M,

c+1 =0

c= -1
For T,

-b -2 =0

b= -2
For L,

a+b-3c-1=0

a=-b+3c+1 a= 2-3+1 a=0

So
1

r p v p p c
c
p . v p2

Following the similar procedure, we will get other two -terms

i.e.

E
p . v p2

H
p . v p2

Based on the dimensional analysis technique, the functional relation

between these three dimensionless products can be given by
1

2 , 3

=f(

i.e.
c
p. v p

c
p. v p

=f

c= p . vp

E
H
,
2
p . v p p . v p2

K1 .

. K1 .

E
p . v p2

Putting the value of

MRR =

) .(

E
p . v p2

H
p . v p2

) .(

H
p . v p2

(8)

c eqn .(7)

. (9a)

Rearranging the eqn. we get

MRR =

Where

K2.

ma p
.
p E

p v
2(u+ v)
( v p)
... (9b)
H

( )( )

1
K2 =
3/4
K1

3
3
, u= 4 a, v= 4 b are constants.

Here, the velocity of the particle again depends upon the radius of the
particle ( r p , air pressure (P), stand of distance (S), mass flow rate (
ma
vp

and time (t).

= f ( r p , P, S, m a , t)

Using Buckingham theorem

No. of variables =6

Physical dimensions are mass, length and time =3

No. of -terms form= 6-3 =3
Here, the repeating variables are 3
i.e. 1. Radius of the particle ( r p )
2. Mass flow rate ( ma )
3. Machining time (t)
Finding 1st -term
1

a
b
c
= r p . ma . t . v p

M 0 L0 T 0
0

M L T

La . ( M T 1 )
b

M L

a +1

c
1
. T .L T

b+ c1

By comparing the powers of M, L&T we get

For M,

b=0

For L,

a+1=0

For T,

-b+c-1=0

a = -1
c=b+1

Putting the value of a, b & c in

1

1 =

c=0+1 =1

r p1 . ma0 . t 1 . v p
v p .t
rp

Following the similar process we will get the value of

i.e. 2
3

2 & 3

P . r p .t
ma

S
rp

The functional relationship between these three dimensionless products

can be given by:1 = f ( 2

3 )

i.e.

v p .t
rp

vp =

K3

=f

P . r p .t S
,
ma
rp

rp
. t .

P . r p .t
ma

S
rp

) .( )

...(10)

v p in eqn.(9b)

Putting the value of

MRR =

( )( )(

m
K2. a . p
p E

p
H

y 2 (u +v)

) ( ))

r P .r p . t
S
K3. p .
.
t
ma
rp

Rearranging the eqn. we get

m a p . r p2
.
MRR =K .
E . t2
p

)(

p .r p 2
H .t 2

) .(

P . r p .t
ma

S
rp

).( )

...(11)

2 (u +v)
Where K= K 2 . K 0
, l=2 x (u+v), m=2 y (u+v) are constants.

The model in eqn. (11) may be considered as the general form of the
material removal rate [MRR] for brittle material, in particular
amorphous glasses. For a given conditions, the constants in the model
needs to be determined from experiments. Based on the experimental
data obtained a multiple regression analysis has been done to determine
the value of constants. The final eqn. to calculate MRR for the machining
of holes on soda lime glass is given by:-

m a p . r p2

.
MRR = .35
p
E .t 2

.6247

) (

p . r p2
H .t2

.733

)(

P.rp.t
ma

.6464

.6916

) ( )
S
rp

By putting the values of all the constants

i.e.,
3
E=70GPa, H=5.5GPa, p=3.21 g/cm ,

We get
.1714
.6464
.6916
MRR =1.306 r p . P . S

t=60s,

m a =.113 g/s

rp

Where

is in m, P is in MPa, S is in mm.
Scatterplot of Actual MRR, Predicted MRR vs Pressure

2.4

Variable sod
A.MRR
1.0
P.MRR
1.0

Material removal rate

2.2

2.0

1.8

1.6

1.4

1.2
0.60

0.62

0.64

0.66

0.68

0.70

0.72

0.74

0.76

Pressure

Scatterplot of Actual MRR, Predicted MRR vs Pressure

1.7

Variable
A.MRR
P.MRR

1.6

Material removal rate

1.5
1.4
1.3
1.2
1.1
1.0
0.9
0.8
0.60

0.62

0.64

0.66

0.68

0.70

0.72

0.74

0.76

Pressure

Scatterplot of Actual MRR, Predicted MRR vs sod

3.5

Variable
A.MRR
P.MRR

Material removal rate

3.0

2.5

2.0

1.5

1.0
0.50

0.75

1.00

1.25

sod

1.50

1.75

2.00

Scatterplot of Actual MRR, Predicted MRR vs sod

4.0

Variable
A.MRR
P.MRR

Material removal rate

3.5

3.0

2.5

2.0

1.5

1.0
0.50

0.75

1.00

1.25

1.50

1.75

2.00

sod
.

Fig.3 Predicted and experimental results for the MRR of hole machining
Conclusion:
Predictive mathematical models for the Material removal rate in hole on
glasses by micro abrasive jets have been developed using a dimensional
analysis technique. A multi-variable regression analysis of the data by
using MATLAB has been done to determine the constants in the models. It
has been shown that the air pressure, stand-off distance and size of
abrasive particle have a positive exponent. It has been shown that the
corresponding experimental data has average deviation of approx. 19%.
These models provide an essential basis for the process optimization of
this micro machining technology to achieve efficient and effective
operations in practise.

**MATLAB codes used in this model.

Rp=1000*(size/2)
E=70
Dp=3.21
H=5.5
t=60
Ma=.113
A1=log(Dp)+(2)*log(Rp)-log(E)-(2)*log(t)

A2=log(Dp)+(2)*log(Rp)-log(H)-(2)*log(t)
A3=log(P.*Rp.*t)-log(Ma)
A4=log(sod./Rp)
O=ones(16,1)
Y=log(MRR)-log(Ma/Dp)
X=[O,A1,A2,A3,A4]
T=X'
I=inv(T*X)
J=T*Y
B=I*J

REFERENCES:[1] H.Z.Li, J.Wang, J.M.Fan, Analysis and Modelling of particle velocities in

micro-abrasive air jet machining, International Journal of Machine Tools &
Manufacture 49 (2009) 850-858.
[2] J.M.Fan, C.Y.Wang, J.Wang, Modelling the erosion rate in micro abrasive
air jet machining of glasses, Wear 266 (2009) 968-974.
[3] A.P.Verma, G.K.Lal, A Theoritical Study of Erosion Phenomenon in
Abrasive Jet Machining,
[4] A. Nouhi, K.Kowsari, J.K.Spelt, M.Papini, abrasive jet machining of
channels on highly-curved glass and PMMA surfaces, Wear 356-357 (2009)
30-39.
[6] H.Getu, A.Ghobeity, J.K.Spelt, M.Papini, Abrasive jet micromachining of
acrylic and polycarbonate polymers at oblique angles of attack, Wear 265
(2008) 888-901.
[7] ] H.Getu, A.Ghobeity, J.K.Spelt, M.Papini, Abrasive jet micromachining
of Polymethylmethacrylate, Wear 263 (2007) 1008-1015
[8] S.Ally, J.K.Spelt, M.Papini, Prediction of machined surface evolution in
the abrasive jet micromachining of metals, Wear 292-293 (2012) 89-99.
[9] N.Shafiei, H.Getu, A.Sadeghian,M.Papini, Computer simulation of
developing abrasive jet machined profiles including paryicle interference,
Journal of material processing technology 209 (2009) 4366-4378.

[10] Huan Qi, Jingming Fan, Jun Wang, Huaizhong Li, On the erosion
process on quartz crystals by the impact of multiple high-velocity microparticles, Tribology International 95 (2016) 462-474.
[11] A.Ghobeity,T.Krajac, T.Burzynski, M.Papini, J.K.Spelt, Surface evolution
models in abrasive jet micro machining, Wear 264 (2008) 185-198.
[12] J.Wang, Predictive depth of jet penetration models for abrasive water
jet cutting of alumina ceramics, International Journal of Mechanical
Sciences 49 (2007) 306316.
[13] Ravindranadh Bobbili, V. Madhu, A.K. Gogia, Modelling and analysis of
material removal rate and surface roughness in wire-cut EDM of armour
materials, Engineering Science and Technology, an International Journal 18
(2015) 664-668.

FOR CHANNEL MACHINING

vp

= f ( r p , P, S, m a , u)

Using Buckingham theorem

No. of variables =6
Physical dimensions are mass, length and time =3
No. of -terms form= 6-3 =3
Here, the repeating variables are 3
i.e. 1. Radius of the particle ( r p )
2. Mass flow rate ( ma )
3. transverse speed (u)

Finding 1st -term

1
M 0 L0 T 0
M 0 L0 T 0

= rp

. ma

La . ( M T 1 )

c
. u . vp
b

1
. ( LT )

1
.L T

M b La +c+1 T bc1

By comparing the powers of M, L&T we get

For M,

b=0

For L,

a+c+1=0

For T,

-b-c-1=0

a = -1-c
c= -(b+1)

c= -0-1 = -1

So , a= -1+1=0
Putting the value of a, b & c in
1

rp

1 =

vp
u

. ma

1
. u . vp

Following the similar process we will get the value of

2 & 3

i.e.
2

P . r p2
u . ma

S
rp

The functional relationship between these three dimensionless products

can be given by:1 = f ( 2
i.e.

vp
u

=f

3 )

P . r p2 S
,
u . ma r p
2 h

vp =

)
i

( ) .( )

P .rp
K4 . u .
u . ma

.(10)

S
rp

..

v p in eqn.(9b)

Putting the value of

MRR =

( )( )(

m
K2. a . p
p E

p
H

2 (u +v)

( ) ( ))

P . r p2
S
K 4 .u .
.
u . ma
rp

Rearranging the eqn. we get

2 u

2 v

P . r p2
u . ma

( )( ) . ( ) . ( )

m a p .u
MRR = K 5 . . E
p
Where

p. u
H

S
rp

...(11)

K 5 = K 2 . K 4 2(u+v ) , j=2 h (u+v), k=2 i (u+v) are constants.