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 KrushnaPrasadPradhan

May11,2009 RollNo10503048

DepartmentofMechanicalEngineering

NationalInstituteofTechnology,Rourkela

 CONTENTS

TITLE PAGENO.

PARTONE 4

1. Introduction 5

2. Equipment 5

3. VariablesinAbrasiveJetMachine 7

4. CharacteristicsofdifferentVariables 7

5. Advantages 8

6. Disadvantages 8

7. Application: 9

PARTTWO 10

1. Literaturesurvey: 11

PARTTHREE 17

1. DESIGNOFCOMPONENTS 18

1. XYTable: 18

2. BallScrew: 22

3. LMGuideorLinearMotionGuideWay: 25

4. SupportUnit: 30

5. NutBracket: 31

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 2. ZAxisAssemblyorVerticalMotionModule: 32

1. LMguideway: 33

2. BallScrew&SupportUnit 34

3. Nozzle 35

4. LimitationsofAbrasiveJetnozzles: 37

3. TOTALASSEMBLY 38

4. OtherComponents 42

i. FRLunit 42

ii. Vibratingunit 43

a. Abrasivecontainer 44

45
b. Cam

5. CostEstimation 46

PARTFOUR 47

1. Nozzle 48

2. Cam 49

3. Abrasivecontainer 49

4. Vibratingassembly 50

CONCLUSION 51

BIBLIOGRAPHY&REFERENCES 52

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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.

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 Part One

INTRODUCTION

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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.

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FIG1:SCHEMATICLAYOUTOFABRASIVEJETMACHINE

Themajorcomponentsare:

1. Aircompressor.

2. Airfilter.

3. Dehumidifier.

4. PressureGauge.

5. PressureRegulator.

6. VibratororMixer.

7. Nozzle.

8. HorizontalandVerticalmotionmodule(forxyzmotion).

9. Arrangementtoholdtheworkpiece.

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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

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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.

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1.6Application:

ThemajorfieldofapplicationofAJMprocessisinthemachiningofessentiallybrittlematerialsand

heatsensitivematerialslikeglass,quartz,sapphire,semiconductormaterials,micaandceramics.Itis

alsousedincuttingslot,thinsections,countering,drilling,deburring,forproducingintegrateshapes

inhardandbrittlematerials.ItisoftenusedforcleaningandpolishingofplasticsnylonandTeflon

components.Delicatecleaning,suchasremovalofsmudgesfromantiquedocuments,isalso

possiblewithAJM.

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 PART TWO

LITERATURE SURVEY

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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.

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 (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

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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
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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

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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

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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.

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 Part Three

DESIGNOFCOMPONENTS

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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.

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FIG2:XYTABLEASSEMBLY(ISOMETRICVIEW)

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FIG3:XYTABLEASSEMBLY(2DVIEWS)

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FIG4:XYTABLE(TOPVIEW)

FIG5:XYTABLE(SIDEVIEW)

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3.1.2BallScrew:

Ballscrewissimilartoleadscrewsuperficiallybutthefrictionisgreatlyreducedincaseofball

screwsbyinsertingrecirculatingballsinbetweenthescrewthreadandthenut.Thethreadprofileis

madecircularandthenutthreadhasgotareverseshapewhichformsaspiralcavityinsidewhichthe

ballsmovewhenthenutisrotated.Oncetheballsreachtheendofthenuttheyareagain

recirculatedbymeansofareturnpipe.Ballscrewscanpreloadedornonpreloaded.Theaccuracy

increasesincaseofpreloadedtypeofballscrewastwosetsofballsarepressedtowardeachother

therebymakingtheradialclearanceclosetozero.

FIG6:RECIRCULATINGBALLSCREW

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Screwlengthcalculation:

TravelofXYtablehasbeendecidedtobe400x350mm.

Soscrewofxaxisballscrew:

= 400mm + 200mm+ 100mm

(Travel) (Uppertablebreadth) (Allowanceforbellowscover)

= 700mm.

Screwlengthyaxisballscrew:

= 350mm + 200mm + 100mm

(Travel) (Upperarrangement) (Bellowscoverallowance)

= 650mm.

CommercialBallscrewsareavailablefromcompanieslike(1)THK,(2)GrampusImpexLtd.,(3)

PrecisionBearingHouse,and(4)ABBAetc.

Thespecificationsbycompaniesthatsatisfyourrequirementare:

BNF20055RRG2850L700C7 (byTHKCompany)

BNF modelno.

20 screwshaftdiameter

05 lead

RR labyrinthsealattached

G2 axialclearancegrade

850L overallshaftlength(inmm)

700 screwlength

C7 accuracysymbol

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SFI2005C7800650P0

SFI modelno.(Singlenut)

20 screwshaftdiameter

05 lead

C7 accuracygrade

800 totallength

650 screwlength

P0 precisionlevel

FIG7:SCREWTHREAD

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FIG8:BALLSCREWASSEMBLY(SHOWINGDIMESIONSANDMACHINEDENDS)

3.1.3LMGuideorLinearMotionGuideWay:

LMGuideasthenamesuggestsisusedforhighlypreciselinearmotion.Itcansustainhighloadsin

anydirectionandhencecanbemountedinanydirection.Theassemblycontainsarailwhichguides

ablockonit.Insidetheblock,ballorrollerarepresentwhichdrasticallyreducesthefrictionallosses.

SoLMGuideispreferredinbothindustriesandroboticstoachievespecificfunctions.

FIG9:LMGUIDEASSEMBLY

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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

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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 (N)

Radialdirection

Reverseradialdirection

Lateraldirection

PR Radialload (N)

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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.

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Raillengthcalculation:

Lengthofrailshouldbeapproximately50mmlargerthanthatofcorrespondingballscrew.

HenceinXaxis:raillength=750mm.

Yaxis:raillength=700mm.

LMGuidesarecommerciallyavailablefromcompanieslike(1)THK,(2)GrampusImpexLtd.,(3)

PrecisionBearingHouse,and(4)ABBAetc.

Thespecificationbycompaniesthatsatisfyourrequirementis:

HSR30R2SSC5700LHII

HSR modelno.

30R sizespecification

2 2blocksperrail

SS endseal+sideseal

C5 radialclearance

700L standardlength

H accuracygrade

II 2rails

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FIG11:DIMENSIONSOFLMGUIDE

3.1.4SupportUnit:

FIG12:SUPPORTUNIT

Supportunitsarerequiredforsupportingtheballscrewends.Thesearespecialkindofbearings

whichgiveslongerservicelifeandbetterperformance.Theyareof2types,

1. Fixedendsupportunit,

2. Supportedendsupportunit.

Infixedendthesupportunitactslikeathrustbearingandtakesallthethrustgivenbythework

load.Inthesupportedendthesupportunitjustactslikesimplebearing.

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Varioustypesofsupportedunitsareavailablecommercially.Theydiffermainlyinthemannerthey

needtobefixedorboltedtoawallorametalplate.Accordinglythefixingholesareprovidedonthe

faceorsidesofthesupportunit.

SupportunitsavailablecommerciallybyTHKaretypeEKforfixedsideandFKforsupportedside.

FIG13:SUPPORTUNIT(DESIGNEF)

3.1.5NutBracket:

Nutbracketisusedtobolttheballscrewnutwiththeworkloadplatform.Followingdiagramshows

anutbracketalongwithaballscrewnut.

FIG14:NUTBTACKET

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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.

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 Supportunit

Pipeholder Ball screw

LMGuide

Nozzleholder

Nozzle

Supportunit

FIG15:VERTICALMOTIONMODULE

3.2.1LMguideway:
TheLMGuideselectedisofthetypeHSRYR.ThespecialfeatureofHSRYRisthatthetappedholes

arepresentonthesideoftheLMBlockandhencetheycanbeattachedtotheloadcomponentfrom

theside.

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FIG16:LMGuide(typeHSRYR)

3.2.2BallScrew&SupportUnit
TheballscrewselectedfortheZaxisassemblyisofthetypeBNT.ThesupportunitsareEKandFK

forfixedendandsupportedendrespectively.ThesmallerspaceintheZassemblydoesntallowfor

theuseofanutbracketfortheballscrewnut.SotheBNTtypeballscrewhasbeenselectedfrom

THKcatalogueasithastappedholesonthenutitselfwhichcanbescrewedtotheloaddirectly.

FIG17:BALLSCREWANDSUPPORTUNIT

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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.

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FIG18:NOZZLE

Nozzletip

Standoff
distance

Workpiece

FIG19:Abrasiveactionofparticles

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3.2.4LimitationsofAbrasiveJetnozzles:
Despitetheirsimpledesign,abrasivejetnozzlescanbetroublesomeattimes.Therearemanydesigns,but

theysharethesameproblems:

1. Shortlifeofanexpensivewearpart

2. Occasionalpluggingofmixingtube:Usuallycausedbydirtorlargeparticlesinabrasive.

3. Wear,misalignment,anddamagetothejewel.

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 3.3TOTALASSEMBLY

Theassemblydrawingoftheabrasivejetmachinecanberepresentedasfollows.Itcanbenoted

thatthecomponentslikeaircompressor,vibrator,dehumidifier,bellowscoverandpipinghavenot

beenshowninthedrawing

FIG20:SIDEVIEWOFWHOLEASSEMBLY

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FIG21:AJMFRONTVIEW

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FIG22:AJMTOPVIEW

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FIG23:AJMISOMETRICVIEW

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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

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3.4.2TheVibratingUnit:

VibratingUnitisusedformixingtheairwiththeabrasiveparticles(Al2O3).TheAbrasive

particlesarestoredinacontainerthroughwhichairisflown.Theparticlesareagitatedby

meansofacamandmotorarrangement.Therotationofcamresultsinvibrationinthe

abrasivecontainer.Theflowrateofabrasivematerialscanbecontrolledbymanipulating

therotationalspeedofthemotor.Theabrasivecontainerwillhaveoneinletandoneoutlet

forairpassageandwillbeverticallysuspendedfromahingedjoint.

SotheVibratingUnitconsistsoffollowingparts

1. Motor(Inductiontype)

2. Cam

3. Abrasivecontainer

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AbrasiveContainer:

FIG25:TheAbrasiveContainer.

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Cam:

Camisfixedwithshaftoftheinductionmotor.Theprofileofthecamistakentobeacircular

one.Thedistancebetweentwocentersasshowninfig26is3mm.Whenthemotorrotates;it

makesthecontainertovibrate.Widthofcamis25mm.

FIG26:Cam

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3.3.5ApproximateCostEstimation:

TABLE:2(Costestimation)

SLNO. NAMEOFTHEITEM COSTPERSINGLE NO.OFITEMS TOTALCOST

PIECE REQUIRED FORTHEITEM

1 Recirculatingballscrew

Xaxis Rs.10,000.00 1

Yaxis Rs.7,000.00 1 Rs.22,00.00

Zaxis Rs.5,000.00 1

2 LinearMotionguideways

Xaxis Rs.17,000.00 1pair

Yaxis Rs.14,000.00 1pair Rs.37,000.00

Zaxis Rs.6,000.00 1

3 SupportUnit

Xaxisballscrew Rs.3,000.00 2

Yaxisballscrew Rs.2,500.00 2 Rs.16,000.00

Zaxisballscrew Rs.2,500.00 2

4 FRLUnit Rs.2,500.00 1 Rs.2500.00

5 Vice Rs.2,000.00 Rs.2,000.00

6 Angles Rs.1000.00 Rs.1000.00

7 Otheraccessories Rs.7,500.00

TOTAL Rs.88,000.00

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 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

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

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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.

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4.5THEVIBRATORASSEMBLY:

Theanglesectionwasweldedwithbaseplatebyarcwelding.Arodwasweldedwithangleorienting

itparallelwithbaseplate.Aninductionmotorwasplacedonthebaseplatebytightenwithnutbolt.

Camwasfixedwithmotorshaft.Thenabrasivecontainerwasconnectedtotherodbymeansofthe

holder.Thecontainerisfreetorotatearoundtherod.

FIG28:Thevibratorassembly

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 CONCLUSION

InthisprojectacompletedesignoftheAbrasiveJetMachineisgiven.TheXYZmotion

modulesaredesignedtakinginaccountofcurrentlyavailablecomponentsinthemarket.

Thedesigningandassemblingofverylargenumberofcomponentswasatremendoustask

andwascompletedontime.Howeverbecauseofsomepartscouldntbepurchasedthe

wholeassemblywaslimitedtodrillingoperation.

Theprojectcangobeyonditscurrentpositionandcapabilitiesbyemployingautomation

intoit.ThiscanbedonebyusingsteppermotorsorDCservomotorsinterfacedwith

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,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

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