Modulee-3: ADVANCED MATERIA

M AL REMO
OVAL PR
ROCESSES
S

Leccture No-3

Abrasive Jet Macchining (AJM

M)

In
n abrasive jeet machining g (AJM) maaterial removval occurs oon account oof impact off high
velocity air / gas stream m of abrasiive particless on the woorkpiece. Thhe abrasives are
prropelled by a high veloccity gas to errode materiaal from the w workpiece. AAs an outcom me of
im
mpact of the abrasive particles
p on
n the workppiece, tiny bbrittle fractuures occur aat the
su
urface of thee workpiece and the carrrier gas carriies away thee fractured frragments. AJJM is
allso called ass abrasive bllasting proceess. It is alsoo known by several other names suuch as
ab
brasive micrro-blasting, pencil
p blastiing and micrro-abrasive bblasting. AJJM is an effeective
machining
m method
m for hard
h and briittle materiaals such as glass, silicoon, tungstenn and
ceeramics. Typ pically the process
p is used for cuttiing intricatee shapes or fforms of speecific
ed
dges. The prrocess is inh herently freee from chattter, vibrationn and heat pproblems beccause
th
he tool neveer touches th he substrate. The schem matic of AJMM process seet up is show wn in
Figure 3.3.1

Advantages
A
  AJM process is a highly flexible process wherein the abrasive media is carried by
a flexible hose, which can reach out to some difficult areas and internal regions.
 AJM process creates localized forces and generates lesser heat than the
conventional machining processes.
 There is no damage to the workpiece surface and also the process does not have
tool-workpiece contact, hence lesser amount of heat is generated.
 The power consumption in AJM process is low.

Disadvantages

 The material removal rate is low

 The process is limited to brittle and hard materials
 The wear rate of nozzle is very high
 The process results in poor machining accuracy
 The process can cause environmental pollution

Applications:

Metal working:

 De-burring of some critical zones in the machined parts.

 Drilling and cutting of the thin and hardened metal sections.
 Removing the machining marks, flaws, chrome and anodizing marks.

Glass:
 Cutting of the optical fibers without altering its wavelength.
 Cutting, drilling and frosting precision optical lenses.
 Cutting extremely thin sections of glass and intricate curved patterns.
 Cutting and etching normally inaccessible areas and internal surfaces.
 Cleaning and dressing the grinding wheels used for glass.

Grinding:
 Cleaning the residues from diamond wheels, dressing wheels of any shape and
size.
Principle of AJM
The principle of machining / cutting by abrasive jet process is explained through the
following steps:
1. Abrasive particles of size between 10 m to 50 m (depending upon the
requirement of either cutting or finishing of the workpiece) are accelerated in a
gas stream (commonly used gas stream is air at high atmospheric pressures).
2. The smaller abrasive particles are useful for finishing and bigger are used for
cutting operations.
3. The abrasive particles are directed through the nozzle, towards the workpiece
surface where-ever cutting or finishing is to be done. The distance between the tip
of the nozzle and the work surface is normally within 1 mm.
4. As the abrasive particles impact the surface of the workpiece, it causes a small
fracture at the surface of the workpiece. The material erosion occurs by the
chipping action.
5. The erosion of material by chipping action is convenient in those materials that
are hard and brittle.
6. As the particles impact the surface of workpiece, it causes a small fracture and
wear, which is carried away by the gas along with the abrasive particles.
7. The abrasive particles once used, cannot be re-used as its shape changes partially
and the workpiece material is also clogged with the abrasive particles during
impingement and subsequent flushing by the carrier gas.