Unconventional Machining Processes:

AJM, EBM, LBM & PAM | Manufacturing

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In this article we will discuss about the unconventional machining processes:- 1.

Abrasive Jet Machining (AJM) 2. Electron Beam Machining (EBM) 3. Laser Beam
Machining (LBM) and 4. Plasma Arc Machining (PAM). And also learn about:-
Unconventional Machining Process, Characteristics of Unconventional Machining
Process and Classifications of Unconventional Machining Processes.

Abrasive Jet Machining (AJM):

In AJM, the material removal takes place due to the impingement of the fine abrasive
particles. These particles move with a high speed air (or gas) stream. Figure 6.1 shows the
process along with some typical parameters of the process. The abrasive particles are
typically of 0.025 mm diameter and the air discharges at a pressure of several atmospheres.

Mechanics of AJM:

When an abrasive particle impinges on the work surface at a high velocity, the impact causes
a tiny brittle fracture and the following air (or gas) carries away the dislodged small work
piece particle (wear particle). This is shown in Figs. 6.2a and 6.2b. Thus, it is obvious that the
process is more suitable when the work material is brittle and fragile. A model for estimating
the material removal rate (mrr) is available. The mrr due to the chipping of the work surface
by the impacting abrasive particles is expressed as –
where Z is the number of abrasive particles impacting per unit time, d is the mean diameter of
the abrasive grains, v is the velocity of the abrasive grains, ρ is the density of the abrasive
material, Hw is the hardness of the work material (the flow stress), and X is a constant.

Process Parameters of AJM:

The process characteristics can be evaluated by judging – (i) the mrr, (ii) the geometry of the
cut, (iii) the roughness of the surface produced, and (iv) the rate of nozzle wear.

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The major parameters which control these quantities are:

(i) The abrasive (composition, strength, size, and mass flow rate),

(ii) The gas (composition, pressure, and velocity),

(iii) The nozzle (geometry, material, distance from and inclination to the work surface).

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We shall now discuss each of these parameters as also their effects:

i. The Abrasive:

Mainly two types of abrasives are used, viz., – (i) aluminium oxide and (ii) silicon carbide.
However, generally aluminium oxide abrasives are preferred in most applications. The shape
of these grains is not very important, but, for a satisfactory wear action on the work surface,
these should have sharp edges. Al2O3 and SiC powders with a nominal grain diameter of 10-
50 μm are available. The best cutting is achieved when the nominal diameter is between 15
μm and 20 μm.

A reuse of the abrasive powder is not recommended as the – (i) cutting capacity decreases
after the first application, and (ii) contamination clogs the small orifices in the nozzle. The
mass flow rate of the abrasive particles depends on the pressure and the flow rate of the gas.
When the mass fraction of the abrasives in the jet (mixing ratio) increases, the mrr initially
increases, but with a further increase in the mixing ratio, it reaches a maximum and then
drops (Fig. 6.3a). When the mass flow rate of the abrasive increases, the mrr also increases
(Fig. 6.3b).
ii. The Gas:

The AJM units normally operate at a pressure of 0.2 N/mm2 to 1 N/mm2. The composition of
gas affects the mrr in an indirect manner as the velocity-pressure relation depends on this
composition. A high velocity obviously causes a high mrr even if the mass flow rate of the
abrasive is kept constant.

iii. The Nozzle:

The nozzle is one of the most vital elements controlling the process characteristics. Since it is
continuously in contact with the abrasive grains flowing at a high speed, the material must be
very hard to avoid any significant wear. Normally, WC or sapphire is used. For a normal
operation, the cross-sectional area of the orifice is between 0.05 mm2 and 0.2 mm2.

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The shape of the orifice can be either circular or rectangular. The average life of a nozzle is
very difficult to ascertain. A WC nozzle lasts between 12hr and 30hr, whereas a sapphire
nozzle lasts for 300hr approximately.  

One of the most important factors in AJM is the distance between the work surface and the
tip of the nozzle, normally called the Nozzle Tip Distance (NTD). The NTD affects not only
the mrr from the work surface but also the shape and size of the cavity produced. Figure 6.5
shows the effect of NTD. When the NTD increases, the velocity of the abrasive particles
impinging on the work surface increases due to their acceleration after they leave the nozzle.
This, in turn, increases the mrr. With a further increase in the NTD, the velocity reduces due
to the drag of the atmosphere which initially checks the increase in the mrr and finally
decreases it. Figure 6.6 shows how the NTD affects the mrr.

The abrasive jet machines are manufactured and marketed by a single manufacturer (namely,
S.S. White Co., New York) under the name “Airbrasive”.   

Characteristics of AJM: