Module-3: ADVANCED MATERIAL REMOVAL PROCESSES

Lecture No-4

Components and Process Parameters in Abrasive Jet Machining

Abrasive jet cutting machines are used in cutting sheet materials or in removing materials
from the surface by generating a focused stream of fluid mixed with the abrasive
particles. They make use of compressed air as the driving fluid in-order to propel the
abrasive particles. Abrasive jet cutting machines are available as complete systems with
all of the components required for blasting or jet machining applications such as pressure
generation / intensification, cabinets, nozzles or wheels and dust collectors. They are
sometimes purchased in component-form to either build a complete customized system or
to replace the worn out parts from an existing system. Abrasive jet cutting machines
includes the following types of devices:

 Gas propulsion device

 Nozzle for delivery of abrasive mix
 Abrasive Collection device

The gas propulsion system provides the supply of clean, dry gas or air to propel the
abrasives particles to the workpiece. In this system care must be taken to have the filters
attached in so that moisture content or any oil or grease contents can be filtered out at the
first stage itself. Also, in this system there must be some arrangement to regulate the flow
of air or gas and the mixture of abrasive particles. The vibrating system is generally
attached to the system so that the abrasive is properly and uniformly mixed with the gas
or air stream. The nozzle used to deliver the mixture at the workpiece should be
manufactured from such materials which can withstand the erosive action of the abrasive
particles and should be wear resistant. The size of the nozzle opening depends upon the
flow rate requirement of abrasive mix on the surface of the workpiece. The abrasive dust
collection system is essential for the safety of the operator. Vacuum based dust collector
system is the most preferred choice. A typical nozzle used in the AJM machines is as
shown in Figure 3.4.1.
Process
P Para
ameters of AJM
A

The
T process parameters in AJM caan be groupped into thee followingg categories.. The
Isshikawa cause and effecct diagram ass shown in ffigure 3.4.2,, depicts the effect of vaarious
prrocess param meters on the
t accuracy y and qualitty of the m machining operations byy the
abbrasive jet machine.
m

1. The Abrasive:
A typ
pes, composiition, strengtth, size, masss flow rate
2. The Gas:
G composiition, pressu ure and veloccity
3. The nozzle:
n geom
metry, material, stand-offf distance (SSOD), feed raate, inclinatiion to
work
4. The workpiece:
w Type
T of materrial

The
T selection t be used iin AJM deppends upon tthe type of work
n of abrasivee particles to
material
m and type of machining
m op
peration whhich needs tto be carrieed out. Diffferent
machining
m op
perations succh as finishiing, roughinng require diifferent typees of abrasivve for
AJM
A operations. Comm monly used abrasive forr cutting innclude alum minum oxidee and
siilicon carbid
de. In cleanin
ng, etching and polishinng operationns glass beaads and dolom mites
arre recommen nded. The siize of the ab
brasive partiicles also plaays an impoortant role inn type
of machining g operations of AJM. Coarse
C grainn particles aare recommeended for cuutting
op
perations while fine graains are recommended for finishing or polishiing operations as
sh
hown in tablle-3.4.1

Table-3.4.1
T Parameters
P in AFM
brasive
Ab Graiin Size App plications
Aluminum Oxide or 10 – 30
0 micron C
Cutting, groooving
Silicon Carrbide
Dolomite and
a glass beaads 5- 10 microns
m E
Etching, polisshing and deeburring

The
T gas used d in the AJJM process must be noon-toxic. It should be ccheap and eeasily
avvailable. Co
ommon typess of gas useed in AJM aapplications are air, nitroogen and caarbon.
The
T recommeended velociity of gas ab brasive mixtuure ranges bbetween 1000 m/sec to 3000 m/
seec dependingg upon the cutting or fin
nishing operaation.

The
T velocity of gas abrassive mixturee is a functioon of nozzle design, nozzzle pressuree, and
ab
brasive partiicle size. Sttand-off distance (SOD)) is a very iimportant paarameter. SO
OD is
defined as th he distance between
b the tip of nozzzle and the w
work surface. The largeer the
SOD the poorrer is the quality and acccuracy of thee cut. The efffect of SOD
D on the accuuracy
of the cut is shown in Figg.3.4.3