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Nozzle design and material in abrasive jet machining process - A review

Article  in  International Journal of Applied Engineering Research · January 2015

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 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.33 (2015)
© Research India Publications; httpwww.ripublication.comijaer.htm

NOZZLE DESIGN AND MATERIAL IN ABRASIVE JET MACHINING PROCESS-A REVIEW

Madhu.S
Associate Professor, Automobile Engineering,Saveetha School of Engineering, Chennai, India-602105

E-mail:mathumarine@gmail.com

ABSTRACT

The abrasive jet machining is a method based on the effects of the fine abrasive particles transported and directed to the
work piece surface by means of compressed air jet. When the dimensions of the machined surface are lower than one
millimeter, the abrasive jet machining could be included in the group of micromachining processes. The nozzle shape,
size, nozzle tip distance are the most important parameters in abrasive air-jet machining equipment. Materials with high
wear resistance will have great potential as abrasive air-jet nozzle materials. In this paper, a Tungsten Carbide,
Sapphire, Stainless steel, and (W,Ti)C/SiC gradient ceramic composite nozzles along with nozzles of different design
which was developed has been studied. The erosion wear behavior of the nozzle was investigated and compared with a
conventional ceramic nozzle. Results showed that the gradient ceramic nozzles exhibited an apparent increase in
erosion wear resistance over the conventional ceramic nozzles. The mechanism responsible was found to be that the
tensile stresses at the entry region of the nozzle were greatly reduced when compared with the conventional nozzle.
This effect may lead to an increase in resistance to fracture, and thus increase the erosion wear resistance of the gradient
nozzle.

Keywords: Nozzle Design, Nozzle Material, Abrasive Jet Machining,

1. INTRODUCTION

Abrasive Jet Machining (AJM) is the process of material removal from a work piece by the application of a high speed
stream of abrasive particles carried in a gas medium from a nozzle. There are two types of abrsive jet machining setup
available. Abrasive jet machining (AJM) is a process of material removal by mechanical erosion caused by the
impingement of high velocity abrasive particles carried by a suitable fluid (usually a gas or air) through a tailer made
shaped nozzle on to the work piece. An AJM set-up may be of two types: one a vortex-type mixing chamber and the
other using a vibratory mixer. In the former, abrasive particles are carried by the vortex motion of the carrier fluid,
whereas in the latter type abrasive particles are forced into the path of the carrier gas by the vibratory motion of the
abrasive particle container. The erosion phenomenon in an AJM may be studied in two phases. The first consists of
transportation phase, i.e. the quantity of abrasive particles flown, and the direction and velocity of impinging particles
as determined by the fluid flow condition of solid-gas suspension. The second phase of the problem is the determination
of the material removal rate or the erosion

2. ABRASIVE JET MACHINING SETUP

Fig -1 SHEMATIC REPRESENTATION OF VERTICAL TYPE ABRASIVE JET MACHINING SETUP

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Fig -2 SHEMATIC REPRESENTATION OF VIBRATORY TYPE ABRASIVE JET MACHINING SETUP

The material removal process is mainly by erosion. The AJM will chiefly be used to cut shapes in hard and brittle
materials like glass, ceramics etc. Abrasives are accelerated by compressed air jet or gases, and are forced through a
nozzle and finally collide with the work piece. The accuracy of the surface structure depends on the accuracy of the
mask, constant flow of abrasives, scan strategy and density and velocity profile of the particle beam. Abrasive jet
micromachining with micro-jet utilizes finer abrasive powders and a smaller nozzle inner diameter.

2. NOZZLE MATERIALS AND DESIGN

Various researchers used different nozzle materials for various applications and process. Tungsten carbide, sapphire,
HCHCr steel, aluminum nozzles for mixing stage, brass and steel nozzles at the exit stage, Stainless steel, Tool Steel ,
deep reactive ion etching (DRIE), Alloy steel (EN38) heat treated of hardness 50 HRC was used for nozzles are used as
nozzle materials for research purpose.

Fig -3 Stainless Steel Nozzle

The Figure shows typical stainless steel nozzle which is having 1.8 mm diameter
Lei Zhang et al[1] had worked with the nozzle material and design. The abrasive particles are directed into the work
surface at high velocity through nozzles. Therefore, the material of the nozzle is subjected to great degree of abrasion
wear and hence these are made of hard materials such as tungsten carbide or synthetic sapphire. Tungsten carbide
nozzles are used for circular cross‐sections in the range of 0.12‐0.8mm diameter, for rectangular sections of size 0.08 x
0.05 to 0.18 x 3.8 mm and for square sections of size upto 0.7 mm. Sapphire nozzles are made only for circular
cross‐sections. The size varies from 0.2 to 0.7 mm diameter. Nozzles are made with an external taper to minimize
secondary effects due to ricocheting of abrasive particles. Nozzles made of tungsten carbide have an average life of 12
to 30 hours while nozzles of sapphire last for about 300 hour of operation.

Jian xin et al[2] explains the nozzle is the most critical part in abrasive air-jet machining equipment. Ceramics,
being with high wear resistance, have great potential as abrasive air-jet nozzle materials. In this paper, a (W,Ti)C/SiC
gradient ceramic composite was developed to be used as nozzle material. The erosion wear behavior of the
(W,Ti)C/SiC gradient nozzle was investigated and compared with a conventional ceramic nozzle. Results showed that
the gradient ceramic nozzles exhibited an apparent increase in erosion wear resistance over the conventional ceramic
nozzles. The mechanism responsible was found to be that the tensile stresses at the entry region of the nozzle were
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greatly reduced when compared with the conventional nozzle. This effect may lead to an increase in resistance to
fracture, and thus increase the erosion wear resistance of the gradient nozzle. It is indicated that gradient structures in
ceramic nozzles are effective to improve the erosion wear resistance of conventional ceramic nozzles in abrasive air-jet
machining

Table 1
Particle size, purity and manufacturer of the starting powders

Starting Average particle Purity Manufacturer

powder size (mm) (%)

SiC 2–3 498.9 Beijing Antai Advanced Tech. and

Materials Co., Ltd.
(W,Ti)C 1–2 499.9 Zhuzhou Cemented Carbide Works

Fig 1. Comparison of Modified and Ordinary Nozzle Design

Ceramics, being highly wear resistant, have great potential as abrasive air-jets nozzle materials. Several studies,
have shown that the entry area of a ceramic nozzle exhibits a brittle fracture-induced removal process, while the center
area shows a plowing type of material removal. As the erosive particles hit the nozzle at high angles at the nozzle entry
section in abrasive air-jet machining, the nozzle entry region suffers from severe abrasive impact, which may cause
large tensile stresses.
Saurabh Verma et al [5] Abrasive jet (AJM) machining process is non-conventional machining process. A focused
stream of abrasive particles carried by high pressure air is made to impinge on the work material is removed by erosion
by high velocity Abrasive particles. In abrasive jet machining process abrasive particles like sand (SiO2), glass beads,
Aluminum oxide, silicon carbide is generally used. Two types of nozzles generally used for average material removal,
tungsten carbide nozzle have a useful life of 12 to 13 hr. and sapphire nozzles have a useful life of 3hr.
Jian xin et al [3] Compared with ceramics such as Si3N4, ZrO2, the strength and fracture toughness of monolithic
SiC ceramic material is rather low. Moreover, the poor sinterability of SiC limits its application because both high
temperature and high pressure are required for a complete densification. In earlier studies, SiC-based composites have
been developed and used in various applications, mechanical properties and microstructure studies on them are also
extensively carried out.
In the present study, the idea of FGMs was introduced to the design of ceramic nozzle. A (W,Ti)C/SiC ceramic
nozzle with gradient structures was produced by hot-pressing. The purpose is to reduce the tensile stress at the entrance
area of the nozzle during abrasive air-jet machin-ing. The erosion wear mechanism of the (W,Ti)C/SiC gradient nozzles
was investigated and compared with that of conventional ceramic nozzles in abrasive air-jet machining.

Fig. 2. The stress distribution in (a) CN-2 conventional nozzle and (b) GN-2 gradient nozzle, in abrasive air-jet
machining calculated by FEM

The tensile stresses at the entry region of GN-2 gradient nozzle are greatly reduced when compared with that of the
CN-2 conventional nozzle. This effect may lead to the increase in resistance to fracture, and thus may increase the
erosion wear resistance of the gradient nozzle. 25528
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The stress along the axial direction of the nozzle decreases from entry to center, and increases from center to exit.
The highest tensile stresses are located at the entry region of the nozzle. While the wear of the nozzle center area
changes from impact to sliding erosion, the tensile stresses caused by the abrasive impact in this area are much smaller
than those at the entry section. Thus, the erosion wear of the nozzle entry region is always serious in contrast with that
of the center area. The most useful is ceramics in modern engineering applications because of its high hardness, high
wear resistance, high melting point, good chemical inertness, high Young’s modulus and thermal conductivity as well
as high thermal shock resistance; these attributes make it a promising candidate for wear resistance components.

F.C. Tsai et al In his study,[5] a nozzle to supply the air stream with the abrasive particles The entire polishing
process is performed under the control of a Visual Basic program installed on a conventional PC. In conducting the
polishing process, the variables include the impact angle of the abrasive jet, the gas pressure, the nozzle-to-work piece
height, the platform rotational velocity, the X–Y platform travel speed, the additive type, and the mixing ratio of the
abrasive material to the additive.In the present Taguchi design, the machining quality is quantified in terms of the
surface roughness following the polishing operation. The polishing result obtained using the AJP process is governed
by six control factors.
A.G. Gradeena et al [10] the resulting abrasive jet temperature was a function of the tubing length and the air
pressure which affected the flow rate. This apparatus was similar to the low temperature gas blast setup. S. Ally et al.,
[16] except that air was used as the carrier gas rather than nitrogen. In the present setup, the abrasive jet temperature
could be controlled by changing the length of the heat exchanger, and the single cooled abrasive jet produced a much
more symmetrical temperature distribution across the blast zone on the target surface.
M. Barletta et al [7]objective is Precision and repeatable machining using AJM, and operating problems can arise,
including chocking regimes, significant nozzle wear, contamination of the atmosphere from dispersed fines, as well as
continuous demand for nozzle replacement.
M. Achtsnick et al[2] A one-dimensional isentropic flow model was developed to calculate the particle exit
velocity of each individual particle in the airflow for two different types of nozzles: a converging cylindrical and a new
developed line shaped Laval-type. The simulation shows that the Laval-type nozzle is able to increase the particle
velocity with more than 30% compared to the converging nozzle. Also the blasting profile is more uniform with a
relatively flat bottom.

Fig 4. Laval nozzle design

For bigger round nozzles a decrease in efficiency has been noticed due to the flux effect. Furthermore, available
pressure feeding systems show lacks through an unsteady particle flow rate. To overcome these shortcomings of
converging and round nozzles, there is a demands on an improved nozzle design.

Deng Jianxin et al [3-4] A SiC/(W,Ti)C ceramic nozzle with gradient structures was produced by hot pressing. The
purpose is to reduce the tensile stress at the entry region of the nozzle in abrasive air-jet. Results showed that the
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gradient ceramic nozzles exhibited an apparent increase in erosion wear resistance over the common ceramic nozzles.
 International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.33 (2015)
© Research India Publications; httpwww.ripublication.comijaer.htm

The mechanism responsible was explained as the formation of compressive residual stresses in nozzle entry region in
fabricating process of the gradient ceramic nozzles, which may partially counteract the tensile stresses resulting from
external loadings.

B. Karpuschewski et al [8] has designed a new line-shaped Laval nozzle has been developed, which is able to increase
the particle velocity by 40% compared to a conventional round nozzle. The blasting-profile of this line-shaped nozzle is
more uniform and the material removal rate is significantly higher compared to conventional nozzles, which in turn
leads to higher achievable aspect ratios of the three-dimensional microstructures. The traverse speed is most effective
parameter for MRR. Abrasive flow rate is also an important parameter for increasing MRR. But beyond some limit with
increase in abrasive flow rate and traverse speed the surface roughness decreases. Increasing traverse speed also
increase the kerf geometry and nozzle wear increases. So it is required to find optimum condition for process parameter
to give better quality of cutting surface.
Computer controlled linear stage Mask
Target support
LN2 Nozzle

Abrasive nozzle

Fig. 6. Schematic of the CAJM process.

H. Getu et al, has found that Cryogenic abrasive jet micromachining of polymers (CAJM) requires sufficient cooling
of the surface region, but over-cooling reduces the cost-effectiveness of the process. CAJM process optimization can be
facilitated by thermal modeling to determine the rate and extent of cooling for a given configuration, and to determine
the effect of thermal strain on the final room-temperature shapes of micro machined features. The analysis showed that
the PDMS was over-cooled and that the CAJM process could be further optimized to conserve LN 2 by decreasing its
flow[11].
Bhaskar Chandra et al[12] in his research work several significant and important papers were focused on either
leading process mechanisms in machining of both ductile and brittle materials. The influence of other parameters, viz.
nozzle pressure, mixing ratio and abrasive size are significant. The SOD was found to be the most influential factor on
the size of the radius generated at the edges. As the NTD increases the diameter of hole increases. Both standoff
distance and the work feed rate show strong influence on the roughness of the machined surface.

In this experiment first we changed the nozzle tip distance (NTD) and observed the effect of NTD on diameter of
holes of work pieces. Secondly we changed the pressure of gas, nozzle material and observed its effect on material
removal rate (MRR) of the work pieces. We had taken readings at different nozzle tip distance (NTD) and different
pressures.
Woojin Song et al [9] has discussed about NPDS, which is a new technique where highly accelerated powders were
utilized to deposit on substrate at room temperature. Conventional powder deposition technologies include aerosol
deposition method (ADM) and cold gas dynamic spray (CGDS) process, but they were limited in powder selection for
deposition. In this study, micron-sized etching phenomenon was explored using NPDS. Two types of flexible
substrates, indium tin oxide (ITO) film and SU-8 resin, were used to investigate the substrate dependence on etching
capability since ITO is widely used as a conductive electrode and SU-8 is widely used as a flexible substrates.

Bhaskar Chandra et al [12-13], This paper presents various results of experiments have been conducted by changing
pressure, nozzle tip distance on different thickness of glass plates, Nozzle material and ceramic plates. It was observed
that for different nozzle material there is no change in the material removal rate (MRR) as it is in the general
observation in the abrasive jet machining process. As the pressure increases the corrosion rate of the nozzle by the
abrasive increases.
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OPTIMUM PROCESS PARAMETERS

N. Jagannatha et al [14] indicated the nozzles are usually made up of Sapphire / Tungsten carbide material of
hardness 50-60 HRC. As the Tungsten carbide material is of high cost, in this research work, alloy steel (EN38) heat
treated of hardness 50 HRC was used for nozzles. The temperature of air at the exit of nozzle is measured using sensors
(Thermocouples).
The optimal combination of process parameters for simultaneous optimization of MRR and Ra is obtained by the
mean values of the multi-response S/N ratio of the overall utility value as shown in Table 4.
Table 4
Process parameters and their levels

Level Level Level

Parameter
1 2 3
A SOD (mm) 4 8 12
B Feed rate (mm/min) 20 30 40
C Air temperature (oC) 27 200 320

Table 5
Observed that there is good agreement between the predicted values and experimental values of optimization. It can
be found that at high temperature, there is a sufficient evidence of more plastic deformation accompanied by brittle
fracture failure which results in increase of MRR and reduction of roughness.

R. Balasubramaniam et al [6] in his research, experiments were performed with a direct pressure type dry abrasive
jet machine mounted on an X:Y table, the specimens being held in a universal type vice. The nozzle was 2 mm_2 mm in
cross-section, 20 mm long and manufactured from OHNS hardened to 55–60 HRC. A height gauge was used to
establish the necessary jet height.
Two series of deburring experiments, each constructed using a Taguchi experimental design array and two sets of
confirmation experiments were performed, the first series to identify the factors causing the burr removal and
maintaining the edge quality and the second series of experiments to identify the factors influencing the magnitude of
the edge radius generated. The results were verified by a confirmation experiment. Five independent parameters viz.
SOD, abrasive size, mixing ratio, nozzle pressure and time were varied in the first experiment of the second series, only
SOD being varied in the confirmation experiment.
D.V. Srikantha, Dr. M. SreenivasaRao et al [17], Nozzles (WC) are designed and fabricated in different sizes( 1
mm,2mm,3mm) . The abrasive grits (Al2o3, Sic) were mixed with air stream ahead of the nozzle and the abrasive flow
rate was kept constant throughout the machining process.
M Balasubramanian, V Jayabalan, V Balasubramanian et al [18] explained about the Mathematical modeling can be
done in the future work to establish a mathematical model, which will give a fair idea of the process.

M Balasubramanian, V Jayabalan, V Balasubramanian et al [19] indicated a cause and effect diagram could be
drawn to interpret the problems associated with the effects.

M Balasubramanian, V Jayabalan, V Balasubramanian et al [20] in their work explained about the central composite
design can be used to decide the optimum number of experiments to be conducted to find out the output.

K Elangovan, V Balasubramanian, S Babu, M Balasubramanian[21] et al explain the Response surface

methodology can be used to optimize the process parameters. Contour plots and response surfaces generated will help
to identify the range of parameters which will maximize or minimize the process parameters.

M.Balasubramanian, V.Jayabalan, V.Balasubramanian[22] et al indicated the Mathematical modeling can be done

in the future work to establish a mathematical model, which will give a fair idea of the process. Response surface
methodology can be used to optimize the process parameters.

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ACKNOWLEDGMENT

The authors hereby thank the authors of the below mentioned references for their valuable contribution which enabled
us to make this comparison.

3. CONCLUSION

All experimental analysis and investigations had done on AJM process. Quality of cutting surface in AJM is
depending on so many process parameters. Production is improved by improving the traverse speed but major problem
with increasing traverse speed is that the nozzle wear is started and the flow of jet is not proper then surface roughness
and kerf quality are decreased. Types of nozzle and nozzle materials affect the efficiency of AJM process. Abrasive
flow rate and types of abrasive also affect the production or MRR.

Efficiency of AJM process is depending on nozzle wear and nozzle wear is depending on so many process
parameter and geometrical parameters. Process parameter which affect less or more on quality of cutting AJM are
pressure, abrasive flow rate, size of abrasive, standoff distance and geometrical parameter as a nozzle length, nozzle
diameter, and nozzle inlet angle, orifice size. Nozzle wear is measured by % exit bore diameter rate and % volume loss
rate of nozzle and quality of cutting surface is measured by material removal rate, surface roughness, kerf width, kerf
taper ratio.
Nozzle failure by erosion wear is generally caused by fracture owing to the large tensile stress at the nozzle entry
zone. Because the nozzle entrance region suffers form severe abrasive impact, and generates large tensile stress. Thus,
the erosion wear of the nozzle depends on the stress distribution in the entry region. Once the maximum tensile stress
exceeds the ultimate strength of the nozzle material, fracture will occur.

4. REFERENCES

[1] Lei Zhanga, Tsunemoto Kuriyagawab, Yuya Yasutomib, Ji Zhaoa “Investigation into micro abrasive
intermittent jet machining International Journal of Machine Tools & Manufacture 45 (2005)
[2] M. Achtsnick a, P.F. Geelhoed b, A.M. Hoogstrate a, B. Karpuschewski Modelling and evaluation of the
micro abrasive blasting process 2005.
[3] Deng Jianxin , Liu Lili, Ding Mingwei Sand erosion performance of SiC/(W,Ti)C gradient ceramic nozzles by
abrasive air-jets 2006.
[4] Deng Jian xin, Wu Feng fang, Zhao Jin Wear mechanisms of gradient ceramic nozzles in abrasive air-jet
machining long February 2007.
[5] Saurabh Verma, F.C. Tsai, B.H. Yan_, C.Y. Kuan, F.Y. Huang A Taguchi and experimental investigation into
the optimal processing conditions for the abrasive jet polishing of SKD61 mold steel 2007
[6] R. Balasubramaniam , J. Krishnan, N. Ramakrishnan b,Investigation Of AJM For Deburring 2007
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AJMPrecision Internal Finishing of Inconel 718 Components
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[9] Woojin Song, Yang-Hee Kim, Min-Saeng Kim, Sung-Hoon Ahn and Caroline Sunyong Lee1, Fine-Sized
Etching of Flexible Substrates Using Nano Particle Deposition System (NPDS) Materials Transactions, (2010)
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[11] H. Getu a, J.K.Spelt b, M.Papini a,n Thermal analysis of cryogenically assisted abrasive jet micromachining
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[13] Bhaskar Chandra Kandpal,Naveen Kumar ,Rahul Kumar, Rahul Sharma, Sagar Deswal Machining Of Glass
And Ceramic With Alumina And Silicon Carbide In Abrasive Jet Machining (2011)
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[14] N. Jagannatha, S.S. Hiremath and K. Sadashivappa Analysis And Parametric Optimization Of Abrasive Hot
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