Materials Today: Proceedings xxx (xxxx) xxx

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Materials Today: Proceedings

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Fabrication and process analysis of working model of abrasive jet

machining
Rohit Pandey ⇑, Nagendra Sharma
Department of Mechanical Engineering, Amity University Madhya Pradesh, Gwalior, M.P 474005, India

a r t i c l e i n f o a b s t r a c t

Article history: Abrasive Jet Machining (AJM) is the process of material removal process of the work piece by using the
Received 24 September 2020 application of high speed steam of abrasive particle carrying with a gas or air medium from a nozzle. The
Received in revised form 19 March 2021 genesis of idea behind this paper is showing to fabricate and analyse process of working model of abra-
Accepted 6 May 2021
sive jet machining by using abrasive particle for multiple mechanical processes like drilling, milling, bor-
Available online xxxx
ing, grinding, surface removal or cutting. This machine uses the flow of abrasive material to strike the
work piece with the fluid (water and air) as medium at high pressure and velocity. This paper shows
Keywords:
the fabrication steps and process analysis of AJM by using various types of process parameters and exper-
Abrasive jet machine
Nozzle
imental analysis.
Abrasive materials Ó 2021 Elsevier Ltd. All rights reserved.
MRR Selection and peer-review under responsibility of the scientific committee of the International Confer-
Abrasive feeder ence on Advances in Design, Materials and Manufacturing.
Machining chamber

1. Introduction through filter and compressor. And after the pressurized air is flow
through the valves and pipe fittings and gets mixed with abrasive
Abrasive jet machining (AJM) is manufacturing processes particles in the meantime after mixing it goes through nozzle and
machine that compring of abrasive erosion and intensification. then mixture and hits the surface of work piece like a blast gun and
AJM plays a great role in the machining technology market. In past perform the machining process. The mixture is in acquired pres-
several years there are numerous papers that talk about this sure and velocity [4].
machining tool. This all explain about the AJM use in many fields
of industries. The particular advanced the rate of micromachining
will be done too many elements using blasting and erosion pro-
2. Jet Machining processes
cess. The material modes that this machine tool can through are
some ductile, brittle, plastic and elastic material mode. The more
In AJM process, the removal rate of material is to be achieved
segmented thoughts were given on the abrasive particles used
directing through a jet of using high velocity with abrasive powder
and the flow medium [1,2]. As we can see that are basically two
on its surfaces. The compressed air is using for the transporting the
types of flow medium are generated one is liquid (water) and other
abrasive particles. Compressed gas transferred as part of energy.
is gas (air). Now the air medium AJM is also known as Abrasive air
The abrasive powder is used to achieve required metal removal
jet machine (AAJM) and the water medium AJM is also known as
rate. The abrasive powder form is a part of compressed ga and
Abrasive water jet machine (AWJM). These machine is generally
stored in the reservious tank. The air is stored into the system
categorized as blasting, mainly blasting that are conventional are
through pressure regulators. It is maintain a constant pressure in
applied to the cold- hardening surfaces but AAJM is aimed to use
the leading to the jet abrasive. The mixing process of the abrasive
as surface removal tool machine [3]. When the machine nozzle
particles with air stream [5]. The mixing chamber is vibrating in
diameter and the machine process diameter is less then 1 mm then
different frequencies and in order to using an electromagnetic
process can be called micro abrasive air jet machine, micro blasting
vibrator to ensuring through mixing of the abrasive particle with
or powder blasting. The air is compressed, pressurized and dried
the air stream. A nozzle is used to direct an abrasive mixture to
achieve the desired velocity for material removal form the work-
⇑ Corresponding author. piece. Anrasive jet machining particles are used for high velocity
E-mail address: pandeyrohit1988@gmail.com (R. Pandey). to achieve desired metal removal rate at high velocity [5,6].

https://doi.org/10.1016/j.matpr.2021.05.151
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Advances in Design, Materials and Manufacturing.

Please cite this article as: R. Pandey and N. Sharma, Fabrication and process analysis of working model of abrasive jet machining, Materials Today: Pro-
ceedings, https://doi.org/10.1016/j.matpr.2021.05.151
R. Pandey and N. Sharma
3. Methodology
AJM is fabricated in the institute workshop with required raw
materials and procured components. In house air compressor and
filter regulator (FR) unit have been used as accessories of the
AJM. Before fabrication design of each component is made. Differ-
ent components designed are mixing chamber, abrasive feeder,
nozzle, work holding devices and glass chamber [7].
3.1. Air compressor
Air compressor compress the air to excessive pressure taking
input power from electric powered motor or inner combustion
engine. In abrasive jet machining excessive stress air jet is required
so that the suspended particles in it can strike the work piece at
excessive velocity. Effective displacing the air compressor work
by using of various forcing air into chamber whose volume reduced
to compress the air. Pistion type compressors use this principle
through using punping air into air chamber by the use of the move-
ment of pistons. They use one-way valves to direct air into cham-
ber the location the air is compressed. Generally air is sucked
besides delay from surroundings. It’s some distance first dried
and made dirt free after which compressed to immoderate pres-
sure. Provider gas strain is saved among 15–20 bar, specially based
at the compressor capacity and jet tempo requirement. Sometime
commercially pure carbon nitrogen or di-oxide gasoline is likewise
used to obtain better cease end results for unique cases [8].
3.2. Carrier gas using in abrasive jet Machining
A Basic cause of carrier fuel in anrasive jet machining is to be
accelerated nice abrasive particles (by momentum transfered). A
compressor is using to maintain the pressure of the service gaso-
line abrasive grit particles are combined with init a mixing cham-
ber (as per mixing ratio) and a nozzle is used to convert stress
strength into the kinetic power (in the shape of high speed jet)
[8]. Carrier fuel stress alongside with nozzle diameter determines
remaining jet speed and therefore machining performance. Among
a range of gases, air is many times used in AJM. It is available easily
and free of cost. It commercially pure nitrogen and carbon di-oxide
are used to harness better performance for a particular purpose [9].
3.3. Functions of carrier gases in abrasive jet Machining (AJM) process
Abrasive jet machining uses excessive velocity (100–300 m/s)
jet of first-class grain abrasive combined with pressurized carrier
gasoline to take away material from work floor by have an effect
on erosion. Such excessive speed jet is received by transforming
static strain of carrier gasoline to kinetic energy. Therefore this car-
rier fuel is first dehumidified and then compressed to very exces-
sive stress (10–20 bar) with the help of air compressor. Abrasive
maintain at the atmospheric pressure are often then mixed with
service fuel to per mixing ratio inside a vibratory mixing chamber.
This combination id then fed to a nozzle which then converts pres-
sure electricity into kinetic strength before discharging it for put-
ting the work surface. Basic functions of provider gases in
abrasive jet machining are mentioned below [10,11].
3.4. Dehumidifer
Dehumidifier is impressive for filtering the air and regulating
the pressure. The coomon impurities suspended in the compressed
air are dust particles of a range of sizes, moisture and oil particles.
Excess moisture current in the pipeline may be end result in coag-
ulation of particles and jam the nozzle opening size. Air filters have
2
Materials Today: Proceedings xxx (xxxx) xxx
a porus membrane having various pores sizes like 5, 10 or 15 mm.
They block the particles larger than the pores material. High pres-
sure air is exceeded via filter regulator lubricating (FRL) unit to dis-
pose of any suspended particles such as dirt or oil. Commonly
compressor is fitted with FRL unit to make the service fuel dry
and dust free. Presence of steam in compressed fuel is enormously
undesirable as it can coagulate and can reason agglomeration of
abrasives throughout waft through pipelines [12].
3.5. Machining chamber
Machining chamber in abrasive jet machining (AJM) is chamber
or we can cover under which the machining of work piece happen
by the AJM. It is a very much essential part of AJM machine. In AJM
machine we can use abrasive particles like some kind of metal,
sand and many more other small particles used hereas abrasive
particles. During the machining process of the work piece there
are 100% of possibilities that after striking to the work piece. These
abrasives particles will move here and there as these particles hav-
ing very high pressure and velocity. These particles have high pres-
sure is mixed with highly compressed air is coming from
compressor and particles have high velocity is coming to the
machining chamber through nozzle. High velocity and pressure
particles move here and there. This movement is very much dan-
gerous because it can harm surroundings like room other compo-
nents of machine and most important. It can led an accident to a
machine operator to avoid these harms machining chamber or
cover is very much important in abrasive jet machining [13,14].
There is also a chimney monted on a machining chamber that is
an essential part of machining chamber the basic use of this is to
remove the pressurized air from machining chamber to the sur-
rounding, abrasive particles and other harmful particles will not
move outside we put of net cloth for filtration so that the air will
move outside but the dust and other harmful particles only goes
to the collecting chamber. Abrasive jet machining (AJM) is a setup
which have different parts like compressor, pressure gauge, abra-
sive, flow regulator, nozzle etc [14].
3.6. Different materials of Maching chamber
There are different materials by which we can make machining
chamber like wood, glass, fiber blass and different types of metals.
There are some factors that we need to take into account. The fac-
tor is what kind of abrasive particles are using and sand then we
can take glass but we taking some kind of metal as abrasive parti-
cles then we cannot use glass these kind of particles can easily
break the glass so for such particles we need a machining chamber
which is more harder than glass like some kind of metal or some
other material. Now there is question arise hereif we use metal
or wood then work piece is not visible for that we make the whole
machining chamber by that material like as a wood and metal but
on some part of it we put some kind of visible material that is
much harder so that we can see the work piece clealy [15].
3.7. Abrasive feeder
Rrquired amount of rough particles is provided by grating fee-
der. The filted charge is encouraged into the blending chamber
where in rough particles are nourished through a strainer. The sif-
ter is made to vibrate at 50–60 Hz and blending proportion is con-
strained by the adequacy of vibration of strainer. The particles are
impelled via transporter gas to a blending chamber. Air rough
blend moves further to spout [15]. The spout grants high speed
to blend which is aimed at work piece surface. By utilizing a care-
fully controlled rough feeder the CNC controller guarantees the
R. Pandey and N. Sharma
Fig. 1. Abrasive Jet Machining Setup.
Fig. 2. Model of Abrasive Jet Machining.
Fig. 3. Air Compressor.
Fig. 4. Abrasive particle flow diagram.
3
Materials Today: Proceedings xxx (xxxx) xxx
definite stockpile of grating for the cutting procedure (Figs. 1–4
and Table 1 and 2).
3.8. Mixing chamber
The high-weight air from the blower is gone through a FRL unit
to removeany debasements. At that point it is sustained to the
grating chamber which has one delta for the incoming packet air
and outlet for blend of rough particles and air. The abrasive parti-
cles are acquainted from the end side so with structure a tornado
to facilitate better blending. The chamber is of round and hollow
shape made up of mellow steel. The creation of blending chamber
is done with the help of end goal that the transporter gas would
enter from three unique gulfs at 1200 point and grating particles
can be enter from the higher point at the blending chamber. This
would bring about violent wind development inside the blending
chamber and homogenous blend of grating particles and trans-
porter gas will be acquired. It is completely shut water/air proof
load witch control the convergence of rough molecule around
piece [16].
3.9. Pressure regulator
The line weight is directed by weight controller. A weight con-
troller has a limiting component a stacking components and an
estimating component. It tends to be a butterfly vlave, globe valve,
popper valve or some other sort of valve that can work as a variable
restriction to the stream. The stacking components apply power to
the limiting componts. It can be a straight forward weight, a spring,
a cylinder actuator, a stomach actuator in combination with a
spring. As the names recommend packet transporter gas weight
must be directed appropriately as define stream speed depends
on it. Stream rate is additionally pivotal papameter that can influ-
ence disintegration rate (or MRR) through blending proportion
[16,17].
3.10. Vibrating unit
Vibrating unit is utilized for blending the air with the rough
particles (Al2O3). The abrasive particles are put away in a holder
through air is flown. The particles are fomented by processes for
a cam and engine course of action. The pivot of cam results in
vibration in the rough holder. The stream pace of grating material
scan is constrained by controlling the rotating speed of the engine
[17]. The abrasive container has one gulf and one outlet for air sec-
tion and will be vertically suspended from a pivoted joint. An abra-
sive is a material regularly a m ineral that is utilized to shape or
complete a workpiece through sourcing which prompts some por-
tion of the workpiece being eroded by grating. While completing a
material regularly means cleaning it to increase a smooth intelli-
gent surface [17].
3.11. Abrasive
The procedure can likewise include roughening as in glossy silk
matte or beaded completions. To put it plainly the earthenware
production which are utilized to cut, crush and clean other milder
materials are known as abrasives. Abrasives are incredibly typical
and are utilized broadly in a huge variety in the physical and syn-
thetic synthesis of abrasivs just as the current stage of the abrasive.
Different sorts of abrasives are utilized in abrasive jet machining
like garnet, aluminum oxide, olivine, silica sand, silicon carbide
and so on. [19].
R. Pandey and N. Sharma
Table 1
Investigating Effect of Various Parameters in AJM.
Velocity (m/sec) Pressure (Pa) Velocity (m/sec)
100 10 120
200 12 150
300 20 160
Table 2
Abrasive Jet Machining Experimental Parameters.
AJM Parameter Condition
Type of abrasive material Sand (SiO2)
Abrasive size 0.25–1.25 mm
Jet pressure 0.6 MPa (6 bars)
Cut off distance 15 mm
Nozzle diameter 1,2,3 mm
Abrasive flow rate 4 g/min
Machining time 30 sec
3.12. Abarasive particles using in abrasive jet machining
In AJM, it has to expect that hard abrasive particles part taking
in material expulsion activity that transporter gas helps to over
whelm dissolved particles from its machining zone. Such abrasives
must have couple of important properties for productive evacua-
tion of material just like nature of cut. Among the different ideal
properties adequate hardness, unpredictable shape, nearness of
great stream and sharp edges attributes are fundamebtal. Various
abrasives have a scope of coarseness size and it can be used depen-
dent on the workpiece material and the various types of activities.
It is planning to perform aluminum oxide (alumina) of normal
coarseness size as 10–50 mm is utilized for penetrating and cutting
activities, particularly when workpiece material is harder. In other
case for exceptionally diligent work materials, silicon carbide (SiC)
is favoring as it is more earnestly than alumina [19]. For cleaning
and evacuation purposes, glass globules and smashed glass are
ordinarily utilized. Bigger coarseness size will produce bigger
depression and hence MRR improves with the penance of surface
completion. Then again fine abrasives lessen material removal
however improving exactness and surface quality [20,21].
4. Conclusion
An extensively reviewed of the recent research and develop-
ment of the AJM has been perfommed in this paper. It shows that
AJM process is received more and more attention in the machining
areas specially for the processing of difficult to cutting materials. It
is various advantages over different conventional and unconven-
tional methods make it a new advancement in the machining
industry. It is followed by the alalysis of various papmeters on
MRR, analytical modeling have reviewed in detail. These analysis
and investigation shows a good knowledge and understanding of
the cutting effectiveness and the associated different aspects of
metal cutting. Results are particular cutting conditions and materi-
als MRR. These advance technologies for modeling like simulation,
taguchi approach etc. this type of process enhancine the cutting
performance and developing new technologies. This typre of mod-
els are developed using an AJM fracture mechanics, erosion mech-
anism and erengy conversion approaches.
CRediT authorship contribution statement
Rohit Pandey: Conceptualization, Investigation, Methodology,
Supervision, Writing - original draft. Nagendra Sharma: Writing
- review & editing.
Materials Today: Proceedings xxx (xxxx) xxx
Friction of Coefficient Wall shear stress Mass flow rate (kg/s)
2.67 9.342 6.00569
3.01 7.092 5.0791
3.35 5.901 4.0173
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
Acknowledgement
Author would like to thank Amity University Madhya Pradesh
Gwalior and Dr. A.P.J. Abdul Kalam University Indore for giving
such a wonderful research facility to perform this research work
and providing experimental facility to perform this type of work
and also thank to MITS Gwalior to provide experimental facilities
for this research paper work.
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DEM-CFD study of the dynamic characteristics of high speed micro-abrasive
air jet, Elsevier Powder Technology.
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abrasive jet machining, (2012) Mechanical Engineering Conference on
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