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Diploma Project
Diploma Project
On
Study on abrsive jet machining
Submitted to
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY, ANANTAPUR
In partial fulfillment of the requirements for the award of
the degree of
BACHELOR OF
TECHNOLOGY IN
MECHANICAL
ENGINEERING
Submitted by
B.Yashwanth (18695A0329)
May 2021
A STUDY ON AJM
DECLARATION
by the B.Tech. Student
I hereby declare that the Technical Seminar Report entitled Study on abrsive jet machining
which is being submitted to the Madanapalle Institute of Technology and Science,
Madanapalle for the award of the Degree of Bachelor of Technology in Mechanical
Engineering is a bonafide report of the presentation prepared by me. The material contained
in this Technical Seminar Report has not been submitted to any University or Institution for
the award of any degree.
Date: 02-06-2021
ABSTRACT
cutting etc., can be carried out effectively and efficiently, to close tolerances.
In this paper, a comprehensive review of work done in this field is given and
complex analytical findings that have been made are highlighted. The
machining process for processing a variety of Hard and Brittle Material. And
CONTENTS
Sl.
Particulars Page No.
No
1. Introduction 01
2. Literatures Survey 02 to 03
6. Process Parameters 15 to 16
8. Machining characteristics 19 to 21
9. Advances in AJM 22
11. Conclusion 24
INTRODUCTION
gas medium from a nozzle. The AJM process differs from conventional sand
blasting in that the abrasive is much finer and the process parameters and
The process is used chiefly to cut intricate shapes in hard and brittle
materials which are sensitive to heat and have a tendency to chip easily. The
process is also used for deburring and cleaning operations. AJM is inherently
free from chatter and vibration problems. The cutting action is cool because
LITERATURE SURVEY
The literature study of Abrasive Jet Machine reveals that the Machining process
was started a few decades ago. Till date there has been a through and detailed
experiment and theoretical study on the process. Most of the studies argue over the
hydrodynamic characteristics of abrasive jets, hence ascertaining the influence of all
operational variables on the process effectiveness including abrasive type, size and
concentration, impact speed and angle of impingement. Other papers found new
problems concerning carrier gas typologies, nozzle shape, size and wear, jet velocity and
pressure, stand‐off‐distance (SOD), or nozzle‐tip‐distance (NTD). These papers express
the overall process performance in terms of material removal rate, geometrical
tolerances and surface finishing of work pieces, as well as in terms of nozzle wear rate.
Finally, there are several significant and important papers which focus on either leading
process mechanisms in machining of both ductile and brittle materials, or on the
development of systematic experimental‐statistical approaches and artificial neural
networks to predict the relationship between the settings of operational variables and
the machining rate and accuracy in surface finishing.
using the commercial code Fluent® 6.3 by Ansys. Dynamic characteristics of the
flow inside the AWJ head and downstream from the nozzle has been
simulated under steady state, turbulent, two‐phase flow conditions. The final
aim is to gain fundamental knowledge of the ultrahigh velocity flow dynamic
features that could affect the quality of the jet, such as the velocity and
pressure distributions in different parts of the AWJ head and at the outlet.
with low and medium level of abrasive flow rate, but the jet failed to cut
carbide since it is too hard and very high level of energy is required. Minimum
rate of abrasive flow that made it possible to cut carbide efficiently was 135 g
min‐1. With increase in jet pressure the surface becomes smoother due to
higher kinetic energy of the abrasives. But the surface near the jet entrance is
smoother and the surface gradually becomes rougher downwards and is the
roughest near the jet exit. Increase in abrasive flow rate also makes the
surface smoother which is due to the availability of higher number of cutting
edges per unit area per unit time. Feed rate didn’t show significant influence
on the machined surface, but it was found that the surface roughness
increases drastically near the jet entrance.
surface finish and higher structural integrity. USM does not produce
thermal, electrical and chemical abnormal surface.
8. Limitations: USM has higher power consumption and lower material-
removal rates than traditional fabrication processes. Tool wears fast in
USM. Machining area and depth is restraint in USM. Laser Beam
Machining (LBM) Laser-beam machining is a thermal material-removal
process that utilizes a high-energy, coherent light beam to melt and
vaporize particles on the surface of metallic and non-metallic
workpieces. Lasers can be used to cut, drill, weld and mark. LBM is
particularly suitable for making accurately placed holes.
12. Abrasive Water Jet Cutting The water jet contains abrasive
particles such as silicon carbide or aluminium oxide in order to increase
the material removal rate above that of water jet machining. Almost
any type of material ranging from hard brittle materials such as
ceramics, metals and glass to extremely soft materials such as foam
and rubbers can be cut by abrasive water jet cutting. This process is
particularly suitable for heat sensitive materials that cannot be
machined by processes that produce heat while machining. This is
similar to water jet cutting apart from some more features underneath
the jewel. In this process, high velocity water exiting the jewel creates
a vacuum which sucks abrasive from the abrasive line, which mixes
with the water in the mixing tube to form a high velocity beam of
abrasives.
DEFINITION:
In abrasive jet machining, a focused stream of abrasive particles,
carried by high pressure air or gas is made to impinge on the work surface
through a nozzle and the work material is made to impinge on the work
surface through a nozzle and work material is removed by erosion by high
velocity abrasive particles.
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
EQUIPMENT:
5. Abrasives
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
For successful utilization of AJM process, it is necessary to analyze the
following process criteria.
1. Material removal rate
2. Geometry and surface finish of work piece
3. wear rate of the nozzle
• 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
a) b) Velocity - 100 to 300 m/s
b) Mixing ratio – Volume flow rate of abrasives/Volume flow rate of gas
c) Stand off distance – SOD- 0.5 to 15mm.
d) 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
1. Material removal rate – 0.015 cm3/min
2. Narrow slots – 0.12 to 0.25mm ± 0.12mm
3. Surface finish -0.25 micron to 1.25 micron
4. 4 Sharp radius up to 0.2mm is possible
5. Steel up to 1.5mm ,Glass up to 6.3mm is possible to cut
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, deburring 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
4. Used for cutting thin fragile components like germanium, silicon etc.
5. Register treaming can be done very easily and micro module fabrication
for electrical contact , semiconductor processing can also be done
effectively.
6. Used for drilling , cutting , deburring etching and polishing of hard and
brittle materials.
7. Most suitable for machining brittle and heat sensitive materials like
glass, quartz, sapphire , mica , ceramics germanium , silicon and
gallium.
8. 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
3. It provides cool cutting action, so it can machine delicate and heat sensitive
material
4. Process is free from chatter and vibration as there is no contact between
the tool and work piece.
5. Capital cost is low and it is easy to operate and maintain AJM.
6. Thin sections of hard brittle materials like germanium, mica, silicon, glass
and ceramics can be machined.
7. It has the capability of cutting holes of intricate shape in hard materials.
Disadvantages /Limitations
1. Limited capacity due to low MRR. MRR for glass is 40 gm/minute.
2 Abrasives may get embedded in the work surface, especially while
machining soft material like elastomers or soft plastics.
3. The accuracy of cutting is hampered by tapering of hole due to unavoidable
flaring of abrasive jet.
4. Stray cutting is difficult to avoid
5. A dust collection system is a basic requirement to prevent atmospheric
pollution and health hazards.
6. Nozzle life is limited (300 hours)
7. Abrasive powders cannot be reused as the sharp edges are worn and
smaller particles can clog the nozzle.
8. Short stand off distances when used for cutting , damages the nozzle.
Machining characteristics
Following are the AJM process criteria
1. Material removal rate
2. Geometry and surface finish of work piece
3. wear rate of the nozzle
As a matter of fact, the material removal rate will increase with the
increase in gas pressure Kinetic energy of the abrasive particles is responsible
for the removal of material by erosion process. The abrasive must impinge on
the work surface with minimum velocity for machining glass by SIC particle is
found to be around 150m/s.
ADVANCES IN AJM
Abrasives are very expensive but abrasive jet process requires low
capital cost and operational cost because the investment on equipment is very
low in comparison with other non-traditional machining processes giving
tighter tolerances. As the carrier gas serves as a coolant, the cutting action is
cool and hence better surface finish can be obtained. Now days it is widely
used in manufacturing of electronic devices, LCD's, tribo-elements, MEMS, and
semiconductors. There exists an increasing demand to develop
micromachining technologies for these difficult – to - machine materials due
to their properties of extreme hardness, brittleness, corrosion resistance and
low melting temperatures. Abrasive jet machining (AJM) is a nontraditional
machine process which operates without producing shocks and heat. In this
machining process, the high - velocity stream of abrasives is generated by
converting the pressure energy of carrier gas or air to its Kinetic energy and
hence the high - velocity jet results. A nozzle directs abrasives in a controlled
manner onto the work material. AJM is applied for many applications like
cutting, cleaning, polishing, deburring, etching, drilling and finishing the
operation. The nozzle is the most critical part in the abrasive air - jet
equipment. The process is used chiefly to cut intricate shapes in hard and
brittle materials which are sensitive to heat and have a tendency to chip
easily. The process can be easily controlled by varying the parameters such as
Velocity, Flow rate, Pressure, Standoff distance, Grit size, and nozzle angle.
Response variables like surface finish, Material Removal Rate(MRR), kerfs
width is producing a cylindrical hole.
TROUBLESHOOTING OF AJM
The AJM differs from sandblasting. In AJM the abrasive is much finer
and the process parameters and cutting action are carefully controlled. Sand
Blasting. Abrasive Jet ... AJM is inherently free from chatter and vibration
problems. The cutting .... deburring of plastics, making of nylon and teflon
Appearance of the dimples during AJM for 10s. for various machining
differ in terms of the removed volume, but also the roughness of the struck
CONCLUSION
The major conclusions that can be drawn from the results of this thesis
can be summarized as follows: & (i) An optimum stand off distance for AJM
exists. This is found from .theory to be within the range of 20-30 mm. The
WEBSITES
4. www.scopus.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