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Abrasive Jet Machining: Definition
Abrasive Jet Machining: Definition
Process:
In Abrasive jet machining abrasive particles are made to impinge on work material at
high velocity. Jet of abrasive particles is carried by carrier gas or air. The high
velocity stream of abrasives is generated by converting pressure energy of carrier
gas or air to its Kinetic energy and hence high velocity jet. Nozzles directs abrasive
jet in a controlled manner onto work material. The high velocity abrasive particles
remove the material by micro-cutting action as well as brittle fracture of the work
material.
In AJM, generally, the abrasive particles of around 50 microns grit size would
impinge on the work material at velocity of 200 m/s from a nozzle of ID 0.5mm with
a stand off distance of around 2mm. The kinetic energy of the abrasive particles
would sufficient to provide material removal due to brittle fracture of the work piece
or even micro cutting by the abrasives.
Equipment:
A schematic layout of AJM is shown above. The gas stream is then passed to the
nozzle through a connecting hose. The velocity of the abrasive stream ejected
through the nozzle is generally of the order of 330 m/sec.
Abrasive Feeder.
Required quantity of abrasive particles is supplied by abrasive feeder. The filleted
propellant is fed into the mixing chamber where in abrasive particles are fed through
a sieve. The sieve is made to vibrate at 50-60 Hz and mixing ratio is controlled by
the amplitude of vibration of sieve. The particles are propelled by carrier gas to a
mixing chamber. Air abrasive mixture moves further to nozzle. The nozzle imparts
high velocity to mixture which is directed at work piece surface.
Machining chamber
It is well closed so that concentration of abrasive particles around the working
chamber does not reach to the harmful limits. Machining chamber is equipped with
vacuum dust collector. Special consideration should be given to dust collection
system if the toxic material (like beryllium) are being machined.
AJM nozzle
AJM nozzle is usually made of tungsten carbide or sapphire ( usually life 300 hours
for sapphire , 20 to 30 hours for WC) which has resistance to wear. The nozzle is
made of either circular or rectangular cross section and head can be head can be
straight, or at a right angle. It is so designed that loss of pressure due to the bends,
friction etc is minimum possible. With increase in wear of a nozzle, the divergence of
jet stream increases resulting in more stray cutting and high inaccuracy.
ABRASIVES
Aluminum oxide (Al2O3) Silicon carbide (SiC) Glass beads, crushed glass and sodium
bicarbonate are some of abrasives used in AJM. Selection of abrasives depends on
MRR , type of work material , machining accuracy.
Process parameters
Abrasives
a) material Al2O3 SiC Glass beads Crushed glass Sodium bi carbonate
b) shape irregular/regular
c) Size 10 to 50 microns
d) Mass flow 2-20 gm/min
Carrier Gas
a) Composition Air, CO2, N2
b) Density 1.3 kg/m3
c) Velocity - 500 to 700 m/s
d) Pressure - 2 to 10 bar
e) Flow rate - 5 to 30 microns
Abrasive Jet
b) Velocity - 100 to 300 m/s
c) Mixing ratio Volume flow rate of abrasives/Volume flow rate of gas
d) Stand off distance SOD- 0.5 to 15mm.
e) Impingement angle 60 to 90 deg.
Nozzle
a) Material WC/Sapphire
b) Diameter 0.2 to 0.8 mm
c) Life 300 hours for sapphire, 20 to 30 hours for WC
Process capability
Applications
1. This is used for abrading and frosting glass more economically as compared to
etching or grinding
2. Cleaning of metallic smears on ceramics, oxides on metals, resistive coating etc.
3. AJM is useful in manufacture of electronic devices , drilling of glass wafers, de
burring of plastics, making of nylon and Teflon parts permanent marking on
rubber stencils, cutting titanium foils
4. Deflashing small castings, engraving registration numbers on toughened glass
used for car windows
5. Used for cutting thin fragile components like germanium, silicon etc.
6. Register treaming can be done very easily and micro module fabrication for
electrical contact , semiconductor processing can also be done effectively.
7. Used for drilling , cutting , deburring etching and polishing of hard and brittle
materials.
8. Most suitable for machining brittle and heat sensitive materials like glass, quartz,
sapphire , mica , ceramics germanium , silicon and gallium.
9. It is also good method for deburring small hole like in hypodermic needles and
for small milled slots in hard metallic components.
Advantages
1. High surface finish can be obtained depending upon the grain sizes
Particle size ( in microns) Surface roughness ( in microns)
10 0.152 to 0.203
25 to 27 0.355 to 0.675
50 0.965 to 1.27
Disadvantages /Limitations
Machining characteristics
abrasive particles is gradually increased exit velocity will go on decreasing for the
same pressure condition. It is due to fact that Kinetic energy of gas is utilized for
transporting the abrasive particle
The effect of mixing ratio on the material removal rate is shown above.
Following assumptions are made in deriving the Material removal models for AJM.
1. Abrasive are spherical in shape and rigid
2. Kinetic energy of particle is completely used to cut the material
3. Brittle material are considered to fail due to brittle fracture and fracture of volume
is considered to be hemispherical with diameter equal to chordal length of
indentation
4. For Ductile material volume of material removal is assumed to be equal to
indentation volume due to particulate impact.
2
dg dg
= + r 2
2 2
2
dg dg
= r 2
2 2
2
r2 = - + d g Neglecting 2 term we
can write
r= dg
Volume of the material removed is the volume of the hemispherical crater due the
fracture is given by
2 3
3 (d g )
1 4 1 4 3
B = r 3 = (r ) 2 = 2
--------------------------------(1)
2 3 2 3
Let us assume that grits also move with velocity (V) then we can write
1 2 1 3 2
Kinetic Energy = KE = 2 M (V ) = 2 6 d g g (V ) --------------------------(2)
1 (d g )
W D by the grit = F = w
2 2
It is assumed that Kinetic energy of the abrasives is fully used for material removal
1 3 2 w (d g )
2 6 d g g (V ) =
2
Simplifying we get
g
= V dg ------------------------------------------------------------------------(5)
6 w
= 2 (d g )2 x
3
Ma
3
(d g )3 g
6
Upon simplifying we get
Ma
MRR =
1 3
( g )4 ( w ) 4
1
D =
2
[
(d g ) ( )2 ]
Mass flow rate of abrasives
MRR = D x
Mass of the abrasive grit
Problem 1 : Estimate the MRR in AJM of a brittle material with flow strength of 4
GPA. The abrasive flow rate is 2 gm/min, velocity is 200m/s, density of abrasive is 3
gm/sec.
Data Given:
Solution
Since the material is brittle. We need to use the MRR formula corresponding to
The brittle material.
3
3
MRRBritlle =
M av = 2 x10 x 200000 2
1 3 1 3
( g )4 ( w ) 4 (3x10 )4 (4 x10 )4
6 9
Data Given:
Material removal rate = 0.5 mm3/sec.
Abrasive grain size = 60 microns = 6x10-3 mm
Mass flow rate of abrasives g = 3gm/min = 3x 10-3/60 kg/sec
3
Mass of grit = 6 dg g
Mass flow rate of abrasives
MRR = Volume of the material removed x
Mass of abrasive grit
3
2 3
0.5x10 = (r ) x
-6
1000 x 60 = 10 microns
3 60 3
3
6 10000 1000 x 10 -6
3x10 3
6x
Number of impact/time = 60 = 254648
3
(
x 50 x10 6 x3000 )
Problem 3: During AJM , Mixing ratio used is 0.2. calculate Mass ratio, if the ratio of
density of abrasives and density of carrier gas is equal to 20.
Solution :
Volume flow rate of abrasive particle
Mixing ratio(MR) =
Volume flow rate of carrier gas
Abrasive mass flow rate
Mass ratio( ) =
combined mass flow rate of abrasive and carier gas
. .
Va Ma a Va
MR = also = =
Vg
.
M a + g V + V.
.
a a g g
. .
g V g
.
1 a Va + g Vg 1 1
Or = = 1+ . = 1 + x
a V a
.
a Va 20 0.2
1
i.e = 1.2 5 or = 0.80
Problem 4: Diameter of nozzle is 1.0mm and jet velocity is 200m/s. Find the
volumetric flow rate ( cm3/sec ) of carrier gas and abrasive mixture.
Volumetric flow rate of carrier gas and abrasive mixture is = area x velocity
= x 25x 2
= 50 cm3 /Sec
Practice Problem
1.Find out the condition for which AJM will produce equal MRR both for ductile and
brittle materials. ( Hint : equate MRR equations and find the condition for critical
velocity)
2.Material removal rate in AJM is 0.3 mm3/sec. calculate MRR/impact if the mass
flow rate of abrasive is 4gm/min, density is 1.5 gm/CC and grit size is 23 microns
Also calculate the indentation radius
3During AJM , Mixing ratio used is 0.3. Calculate Mass ratio, if the ratio of density
of abrasives and density of carrier gas is equal to 10
Review Questions
1. With the help of neat diagram explain Abrasive jet machining system
and label the parts.
2. What are the advantages and limitations of AJM?
3. Discuss the effect of following process parameters on MRR
SOD and MRR
Effect of abrasive grain size and flow on MRR
Effect of Nozzle pressure for various MR on MRR
Effect of Mixing ratio on MRR
6. Derive an expression for MRR in AJM for brittle material
7. Write at least five application of AJM in Industry
8. State clearly the process capability of AJM
9. Define AJM. What is the principle of Abrasive jet machining
10. Write the applications of different types of abrasives used in AJM.
11. Write five important variables of AJM process. Draw a sketch showing the effect
of these variables on MRR
12. Explain the working principle of AJM process
13. With the help of sketches, show the effect of stand off distance on MRR.