Abrassive Jet Machine Project Report

DESIGN AND FABRICATION OF
ABRASIVE JET MACHINE

A Project Report
submitted by
AB BASIT 19204135022
UMMAR YOUSUF 19204135042
YAWER NABI BHAT 19204135025
ZAHID FAYAZ 19204135006
JOSY AKHTER 19204135029
HEENA GUL 19204135048
Under the guidance of
ER. SUHAIL SHAHZAD
In partial fulfillment for the award of the
degreeof
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
at
SSM COLLEGE OF ENGINEERING
PARIHASPORA, PATTAN, BARAMULLA KAHSMIR
(AFFILIATED TO UNIVERSITY OF KASHMIR)
OCTOBER, 2023
2023
DESIGN AND FABRICATION OF ABRASIVE JET MACHINE
DECLARATION
We hereby declare that the project entitled “DESIGN AND FABRICATION OF ABRASIVE JET
MACHINE” submitted for the B.E. (MECHANICAL) degree is our original work and the project has not
formed the basis for the award of any other degree, diploma, fellowship or any other similar titles.
Signature of the Student
Date:
DEPARTMENT OF MECHANICAL ENGINEERING ii

2023
CERTIFICATE
This is to certify that the project entitled
SUBMITTED BY
AB BASIT 19204135022
UMMAR YOUSUF 19204135042
YAWER NABI BHAT 19204135025

ZAHID FAYAZ 19204135006
JOSY AKHTER 19204135029
HEENA GUL 19204133048
Is the bonafide carried out by them under the supervision of ER. SUHAIL SHAHZAD, and is approved for
the partial fulfillment of the requirement for the award of the degree of Bachelor of engineer
(MECHANICAL engineering) of SSM college of engineering, Kashmir affiliated to University Of Kashmir,
Srinagar during the academic year 2022-2023
This Project Report has not been earlier submitted to any other institute or university for the award
Of any Degree.
Mr. Mohammad Nayeem Dr. Sajaad Hussain
Head principal
Department of Mechanical Engineeing
Er. Suhail Shahzad
Project guide
Department of Mechanical Engineering
DEPARTMENT OF MECHANICAL ENGINEERING iii

2023
ACKNOWLEDGEMENT
Words are not just enough to express our gratitude but we take this opportunity to express our profound
sense of gratitude and respect to all those who helped us throughout the duration of this project. We
acknowledge the effort of those who have contributed significantly to our project.
First of all we are very thankful to our Parents for their regular support and guidance we are also very
thankful to God for providing us such a great opportunity to do the Project in college.
we feel privileged to offer our sincere thanks and deep sense of gratitude to ER. SUHAIL SHAHZAD,
project Guide, for expressing their confidence in us by letting us work on a project of this magnitude and using
latest technologies and providing their support, help & encouragement in implementing this project.
Last but not the least, we are grateful to all our friends for providing critical feedback & support whenever
required.
There are times in such projects when clock beats the time and we run out of energy, we just want to finish
it once and forever, Suhail Sir, Parents and Friends made us endure such times with their unfailing humor &
warm wishes.
DEPARTMENT OF MECHANICAL ENGINEERING iv

2023
ABSTRACT
Abrasive jet machining (AJM) is the one of the modern machining processes in various industries for difficult
to machine materials. AJM is a non-conventional machining process in which removal of material takes place
by impact of high speed stream of abrasive particles carried in gas or air modem from a nozzle. The different
components of AJM such as nozzle pressure regulator, and air filter, mixing chamber are fabricated with
appropriate design calculations. This abrasive jet machining project is used for cutting any integrated shapes
on brittle materials like glass. We can cut any difficult shapes and create holes in glass and brittle material
using compressed air and abrasive particles. Here we make use of a combination of two abrasive materials. A
Compressor is used to supply the pressurized air to Air filter. The Air filter cleans the air and removes any
moisture content, thus providing clean dry air. The air is passed through PU pipe to Control Valve, which
controls the air through pipes to the mixing chamber. There is a pressure gauge which is attached to measure
the pressure through the pipe. The function of the mixing chamber is to mix the Abrasive with the supplied
clean Air with high pressure and is achieved by using an induction motor, connected through an arm with the
mixing chamber. As the motor starts working the arm rotates providing motion to the chamber and thus helps
in effective mixing of abrasives. Discharge of this mixing chamber is supplied to the nozzle through a pipe.
Nozzle increases the velocity of high pressurized discharge (air mixed with abrasive particles). The abrasive
particles are directed into the work surface at high velocity through the nozzle and are able to erode material
off the work piece’s surface.
DEPARTMENT OF MECHANICAL ENGINEERING v

DESIGN AND FABRICATION OF ABRASIVE JET MACHINE 2023
TABLE OF CONTENT
Title
Declaration II
Certificate III
Acknowledgement IV
Abstract V
Table of content VI-VII
List of figures VIII
List of tables IX
CHAPTER 1 - INTRODUCTION
Problem definition 1
Principle of AJM 1-2
Equipment 2
Variables in AJM 3-4
Characteristics of different variables 4
Applications of AJM 4-5
Advantages 5-6
Disadvantages 6
Machining characteristics of AJM 6
Effect of abrasive flow rate and grain size on MRR 6-7
Effect of exit gas velocity and abrasive particle density 7
Effect of mixing ratio on MRR 8
Effect of nozzle pressure on MRR 8
Effect of standoff distance on MRR 9
CHAPTER 2 – LITERATURE SURVEY
Existing system 10-12

Project methodology 12-13
Abrasive jet machining methodology 13
CHAPTER 3 – DESIGN OF COMPONENTS
Air compressor 14-21

History and its classification 14-16
Reciprocating Compressors 16
DEPARTMENT OF MECHANICAL ENGINEERING vi

Piston Compressors 17-21

FRL Unit 21-22
The vibrating unit 22
Induction motor 22-23
Nozzle 23
CNC (Mechanism) 23-24
Machining chamber 24
Fabrication and assembly 24-25
Abrasives and their specifications 26-29
CHAPTER 4 - DESIGN EXPERIMENTS
Selection of control variables 30-32
Selection of response variables 33
Experimental procedure 33
CHAPTER 5 – RESULTS 34-36
CHAPTER 6 – CONCLUSION 37
CHAPTER 7 – REFERENCES 38
DEPARTMENT OF MECHANICAL ENGINEERING vii

LIST OF FIGURES
Fig. 1 Principle of AJM
Fig. 2 schematic diagram of AJM
Fig. 3 Effect of Abrasive Flow Rate on MRR
Fig. 4 Effect of Exit Gas Velocity and Abrasive Particle Density
Fig. 5 Effect of nozzle pressure on MRR
Fig. 6 Effect of SOD on Machined Profile
Fig. 7 Single Stage Compressor
Fig. 8 Types of Compression
Fig. 9 P V Diagram.
Fig. 10 PV Diagram with Clearance

Fig 11 Air Compressor
Fig 12 FRL (Air Filter)
Fig. 13 Vibrating Unit
Fig 14: Mixing Chamber
Fig 15: Induction Motor

Fig 16: Nozzle
Fig 17: CNC Machine
Fig 18: Machining Chamber
Fig 19: Abrasive Container
Fig 20: The Vibrator Assembly

Fig 21: Glass Beads
Fig 22: Walnut Powder
Fig 23: Crushed Bones

Fig 24: Representation of Various Graphs
Fig 25: Effect of SOD
DEPARTMENT OF MECHANICAL ENGINEERING viii

LIST OF TABLES
Table 1: Characteristics of Different Variables
Table 2: Particle Size and Surface Roughness
Table 3: Abrasive Machine Parameters
Table 4: Reciprocating Compressor Specifications
Table 5: Abrasives Used
Table 6: Conversion Table
DEPARTMENT OF MECHANICAL ENGINEERING ix

CHAPTER-1
INTRODUCTION
PROBLEM DEFINITION
Abrasive Jet Machine is the removal of the material from a work piece by the application of a high speed
steam of Abrasive particles carried out in gas medium from a nozzle. The application of a high speed stream
of abrasive particles carried in 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 cutting action are carefully
controlled.
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 the carrier gas
serves as a coolant.
Abrasive Jet Machining (AJM) presents the working of abrasive jet machining and removing materials from
the brittle and heat sensitive materials by the application of a high speed stream of abrasive particles carried
by a gas medium through the nozzle. In particular drilling of holes of minimum diameter and maximum
depth is also possible in AJM with greater accuracy and surface finish. Since no heat is induced while
machining the surface, the workplace is not subjected to thermal shocks. The abrasive jet machining
apparatus can be used for determining the material removal rate (MRR) for materials like glass, ceramics
and aluminum sheet by varying the parameters like pressure, nozzle tip distance (NTD) and size of the
abrasive flow rate.
AJM differs from sand blasting. In AJM the abrasive is much finer and the process parameters and cutting
action are carefully controlled.
PRINCIPLE OF AJM:
This machining process works on the basic principle of abrasive erosion. If a high velocity abrasive particles
strike on a hard or brittle work piece, it removes some metal at the striking surface. This metal removal
process takes place due to brittle fracture of metal and also due to micro cutting by abrasive particle. This is
principle process of abrasive jet machining.
If this is a work surface [fig.2] which is to be either cut or finished. Then the abrasive jet, one abrasive jet
will be just forced from this nozzle. So, this is the nozzle. Nozzle and this will be directed towards this
surface, this is we call that target surface and this will beat very high speed. This will be moving towards the
surface and here a gas will be there which is in most of the cases it is air or it can be a argon gas or it can be
DEPARTMENT OF MECHANICAL ENGINEERING 1

other generally neutral gas plus abrasive materials.
Fig 1: Principle of AJM
Here in this process there are several factors which are very, very important. One important factor is this
distance and then the angle of this nozzle at which it is striking this work surface. Of course, the
concentration of the abrasive particles with this gas is also another important factor, but the limitation,
basic limitation of this process is that this material, work material should be preferably brittle like say
glass, etcetera. In these brittle materials, this brittle fracture phenomenon occurs more readily and we get
measuring effect more prominently. This process is also known by several other names like abrasive micro
blasting, pencil blasting, micro abrasive blasting etcetera. This abrasive jet machining process is an
effective measuring matter for hard and brittle materials such as glass, silicon, tungsten and ceramic. As
we know tungsten and tungsten carbide these materials are very, very hard and very difficult to be
machined by other machining methods. However, this process like abrasive jet machining process is useful
for machining or at least finishing these materials like tungsten carbide or tungsten, tungsten or silicon
etcetera apart from of course, glass.
Equipment:
A schematic layout is shown in figure [1] 'The filtered gas, supplied under pressure to the mixing chamber
containing the abrasive powder and vibrating at 50 c/s, entrains the abrasive particle and is the passed into
a connecting hose. This abrasive and gas mixture emerges from a small nozzle at high velocity. The
abrasive powder feed rate is controlled by the amplitude of vibration of the mixing chamber. A pressure
regulator controls the gas flow and pressure.
The nozzle is mounted on a fixture. Either the workpiece or the nozzle is moved by cams pantograph or
other suitable mechanisms to control the size and shape of the cut. Hand operation is sometimes adequate
to remove surface contaminations or in cutting where accuracy is not very critical. Dust removal
equipment is necessary to protect the environment. Commercial bench mounted units including all
controls, motion producing devices, and dust control equipment are available.

Fig 2: Schematic Layout of AJM

The major components are:
1. Air compressor
2. Air filter
3. Pressure regulator
4. Control valve
5. Mixing chamber
6. Induction Motor
7. Nozzle
8. Arrangement to hold the work piece
9. CNC
Variables in Abrasive Jet Machine
The variables that influence the rate of metal removal and accuracy of machining in this
Process is
1. Carrier gas
2. Types of abrasive
3. Size of abrasive grain
4. Velocity of abrasive jet
5. Flow rate of abrasive
6. Work material
7. Geometry, composition and material of nozzle

8. Nozzle work distance (stand-off distance)
9. Shape of cut and operation type
CHARACTERISTICS OF DIFFERENT VARIABLES:
Carrier gas Air
Abrasive Glass beads, Crushed walnut shells,

Crushed bones
(of size20-50 microns)
Flow rate of 2-20gm/min.
abrasive
Velocity 150-300m/sec.
Pressure 2-10kgf/cm2
Nozzle size 1-2mm
Nozzle material Tungsten carbide, Brass
Nozzle life 20-30hours
Standoff 0.2-15mm
distance
Work material Non-metals like glass, ceramic and alumina
Ceramic, acrylic.
Metals like Tin
Application Drilling, cutting and
cleaning.
Table 1: Characteristics of Different Variables
Application of AJM
1. AJM is used for abrading and frosting glass, ceramics and refractories 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, debarring of plastics, making
of nylon and Teflon parts, permanent marking on rubber stencils, cutting titanium foils.
4. De flashing small castings and trimming of parting lines of injection molded parts and forgings.

5. Use for engraving registration numbers on toughened glass used for car windows. 6. Used for cutting thin
fragile components like germanium, silicon, quartz, mica, etc.
7. Micro module fabrication for electrical contact, semiconductor processing can be done effectively.
8. Used for drilling, cutting, de burring etching and polishing of hard and brittle materials.
9. Most suitable for machining brittle and heat-sensitive materials like Glass, Quartz, Sapphire, Mica,
Ceramics, Germanium, Silicon and Gallium.
10. It is also good for de burring small holes like in hypodermic needles and for small milled slots in
hardmetallic components.
11. It can be used for micromachining of brittle materials.
12. It is used in fine drilling and aperture drilling for electronic microscope.
13. Used for cleaning metallic moulds and cavities.
14. Cleaning surfaces from corrosion, paints, glues and other contaminants, especially those that are
inaccessible.
15. De burring of surgical needles and hydraulic valves, nylon, Teflon and derlin.
16. Engraving on glass using rubber or metallic masks.
Advantages of AJM
1. High surface finish can be obtained depending upon the grain size
Particle size(in microns) Surface roughness (in microns)
10 0.152-0.203
25-27 0.355-0.675
50 0.965-1.27
Table 2: Particle Size and Surface Roughness
2. Depth of damage is low (around 2.5 microns).
3. It provides cool cutting action, so it can machine delicate and heat-sensitive material such as glass and
ceramics. They can be machined without affecting their physical properties and crystalline structure.
4. Process is free from chatter and vibration as there is no contact between the tool and the 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 and brittle materials.
8. The abrasive jet process produces surfaces which have high wear resistance.
Disadvantages
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 and hence accuracy is not good.
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.
9. The process accuracy is poor because of flaring effect of the abrasive jet.
10. Deep holes will have an unacceptable taper.
11. The process is not environment-friendly and causes pollution.
12. Some hazards are involved in using the AJM process because of airborne abrasive particulates. By
using abrasive water jet machining this problem can be solved.
Machining Characteristics of AJM
Following are the AJM process criteria:
1. Material removal rate
2. Geometry and surface finish of the work piece.
3. Wear rate of the nozzle
Process criteria are generally influenced by the process parameters. The characteristics of the above
process parameters on process criteria are as follows.
Effect of abrasive flow rate and grain size on MRR:

It is clear from the figure that at a particular pressure MRR increases with increase in abrasive flow rate
and is influenced by the size of the abrasive particles. But after reaching optimum value, MRR decreases
with further increase in abrasive flow rate.

Fig 3: Effect of Abrasive Flow Rate on MRR
This is owing to the fact that mass flow rate of gas decreases with increase of abrasive flow rate and hence
mixing ratio increases causing a decrease in material removal rate because of decreasing energy available for
erosion.
Effect of exit gas velocity and abrasive particle density
The velocity of carrier gas conveying the abrasive particles changes considerably with the change of
abrasive particle density as indicated in figure.
Fig 4: Effect of Exit Gas Velocity and Abrasive Particle Density
The exit velocity of gas can be increased to critical velocity when the internal gas pressure is nearly twice
the pressure at exit of nozzle for the abrasive particle density is zero. If the density of abrasive particles is
gradually increased exit velocity will go on decreasing for the same pressure condition. It is due to the fact
that kinetic energy of gas is utilized for transporting the abrasive particles.

Effect of mixing ratio on MRR:

Increased mass flow rate of abrasive will result in a decreased velocity of fluid and will thereby
decrease the available energy for erosion and ultimately the MRR. It is convenient to explain this fact by
term mixing ratio. Which is defined as
Volume flow rate of abrasives per unit time

Mixing ratio=
Volume flow rate of carrier gas per unit time
The material removal rate can be improved by increasing the abrasive flow rate provided the mixing ratio is
kept constant. The mixing ratio is unchanged only by simultaneous increase of both gas and abrasive flow
rate.
An optimum value of mixing ratio that gives maximum MRR is predicted by trial and error. In place of
mixing ratio, the mass ratio a may be easier to determine. Which is defined as
𝖺 = Volume flow rate of abrasive

Volume flow rate of carrier gas
Where,
Volume flow rate of abrasives = ma
Volume flow rate of carrier gas= ma+mg
Effect of nozzle pressure on MRR
The abrasive flow rate can be increased by increasing the flow rate of the carrier gas. This is only possible
by increasing the internal gas pressure as shown in the figure. As the internal gas pressure increases abrasive
mass flow rate increases and thus MRR increases. 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 150 m/s.
Fig 5: Effect of nozzle pressure on MRR

Effect of standoff distance on MRR

High velocity abrasive jet, after discharging from the nozzle, remains intact for a small distance and then
starts spreading as the surrounding pressure is substantially lower than the stagnation pressure of the jet.
Thus the diameter of abrasive jet expands gradually with increase in distance from nozzle tip and
consequently velocity (or kinetic energy) of the jet reduces. Therefore, smaller SOD provides a narrow and
high velocity jet; whereas, larger SOD provides a wider and low velocity jet. Consequently, smaller SOD
can cut a deeper but narrow slot or hole; while larger SOD can cut a shallow but wider area (suitable for
cleaning of oxides, removing coating, etc.). The same is depicted in the figure below.
Fig 6: Effect of SOD on Machined Profile

CHAPTER 2
LITERATURE SURVEY:
Existing system:
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.
The study of the results of machining under various conditions approves that a commercial AJM machine
was used, with nozzles of diameter ranging from 1-2 mm, the nozzle materials being either tungsten carbide
or brass, both of which have good tool lives. Glass beads, walnut shells, bones were the abrasives used.
Other parameters studied were nozzle tip distances (0.2-15 mm), spray angles (90° and pressures (2-10 bars)
for materials like glass, ceramics, acrylic, Wood, Tin etc. The holes drilled by AJM may not be circular and
cylindrical but almost elliptical and bell mouthed. High material removal rate conditions do not necessarily
yield small narrow clean-cut machined areas.
Studies reveal that AJM is an attractive micro-machining method for ceramic materials. The machinability
during the AJM process can be compared to that given by the established models of solid particle erosion, in
which the material removal is assumed to originate in the ideal crack formation system. However, it was
clarified that the erosion models are not necessarily applicable to the AJM test results, because the relative
hardness of the abrasive against the target material, which is not taken into account in the models, is critical
in the micro-machining process. No strength degradation took place for the AJM ceramic surfaces. This is
attributed to the fact that radial cracks did not propagate downwards by particle impacts during the
machining process.
Abrasive Water Jet (AWJ) turning is a technology that still tries to find its niche field of application where it

can be economically viable. But a particular application of AWJ turning has proved its technological and
economical capability, i.e. profiling and dressing of grinding wheels. Starting from the theoretical
considerations, the key operating parameters of AWJ turning are identified and included in a methodology to
generate various profiles of grinding wheels by means of tangential movement of the jet plume. Roughing in
single pass to concave/convex geometries (experimented depth of cuts < 30 mm), generation of thin
walls/slots (thickness < 2 mm, depth > 430 mm) and intricate profile (e.g. succession of tight radii) on a
variety of grinding wheels show the capability of AWJ turning to fulfil the requirements of this niche
application.
The machining process produces no heat and hence changes in microstructure or strength of the surface is
unlikely. The air acts as a coolant and hence AJM process has a high potential as damage free
micromachining method. The fracture toughness and hardness of the target materials are critical parameters
affecting the material removal rate in AJM. However, their influence on the machinability varied greatly
with the employed abrasives. In recent years abrasive jet machining has been gaining increasing
acceptability for deburring applications. The influence of abrasive jet deburring process parameters is not
known clearly. AJM deburring has the advantage over manual deburring method that generates edge radius
automatically. This increases the quality of the deburred components. The process of removal of burr and the
generation of a convex edge were found to vary as a function of the parameters jet height and impingement
angle, with a fixed SOD. The influence of other parameters, viz. nozzle pressure, mixing ratio and abrasive
size are insignificant. The SOD was found to be the most influential factor on the size of the radius generated
at the edges. The size of the edge radius generated was found to be limited to the burr root thickness. (Ref.-
15) Abrasive jet finishing combined with grinding gives rise to a precision finishing Process called the
integration manufacturing technology, in which slurry of abrasive and liquid solvent is injected to grinding
zone between grinding wheel and work surface under no radial feed condition. The abrasive particles are
driven and energized by the rotating grinding wheel and liquid hydrodynamic pressure and increased slurry
speed between grinding wheel and work surface achieves micro removal finishing.
Abrasive waterjet machines are becoming more widely used in mechanical machining. These machines offer
great advantages in machining complex geometrical parts in almost any material. This ability to machine
hard-to-machine materials, combined with advancements in both the hardware and software used in waterjet
machining has caused the technology to spread and become more widely used in industry. New
developments in high pressure pumps provide more hydraulic power at the cutting head, significantly
increasing the cutting performance of the machine. Analysis of the economic and technical has been done by
researchers. Those technology advancements in applying higher power machining and intelligent software
control have proven to significantly improve the overall performance of the abrasive water jet machining
operation, thus widening the scope of possible applications of this innovative and promising technology.

Quality of the surface produced during abrasive water jet machining of aluminium has been investigated in
recent years. The type of abrasive used was garnet of mesh size 80.
The cutting variables were stand-off distance of the nozzle from the work surface, work feed rate and jet
pressure. The evaluating criteria of the surface produced were width of cut, taper of the cut slot and work
surface roughness. It was found that in order to minimize the width of cut; the nozzle should be placed close
to the work surface. Increase in jet pressure results in widening of the cut slot both at the top and at exit of
the jet from the work.
However, the width of cut at the bottom (exit) was always found to be larger than that at the top (at a stand-
off distance of 3 mm and the work feed rate of 15 mm min-1). It was found that the taper of cut gradually
reduces with increase in stand-off distance and was close to zero at the stand-off distance of 4 mm (at a jet
pressure of 30 psi and a work feed rate of 15 mm min-1). The feed rate of the work should be kept within 40
mm min-1 (at the jet pressure of 30 psi and the stand-off distance of 3 mm), because a feed rate beyond 40
mm min-1 results in sharp increase in taper angle. The jet pressure does not show significant influence on
the taper angle within the range of work feed and the standoff distance considered. Both stand-off distance
and the work feed rate show strong influence on the roughness of the machined surface. Hence stand-off
distance should be kept within 3 mm (at a jet pressure of 30 psi and a work feed rate of 15 mm min-1) and
the work feed rate should be kept within 30 mm min-1 (at a jet pressure of 30 psi and a standoff distance of 3
mm) in order to have a good surface finish, since beyond those values of the parameters the roughness of the
machined surface rises sharply. Increase in jet pressure shows positive effect in terms of smoothness of the
machined surface. With increase in jet pressure, the surface roughness decreases (at a stand-off distance of
3mm and work feed of 15 mm min-1). So within the jet pressure considered, the work surface is smoother
near the top surface and gradually it becomes rougher at higher depths.
Project Methodology:
Brittle and hard solids can be classified in four groups: minerals, polycrystalline ceramic aggregates
(traditional and advanced), single crystals and amorphous glasses. Minerals are frequently used as raw
materials in the production of a large range of products such as abrasives, gemstones, metals and alloys,
single crystals synthetically produced on a commercial scale, etc. Traditional ceramics and glasses are
extensively used to manufacture many products currently used in daily life. Advanced ceramics have been
widely adopted as functional as well as structural engineering materials (Chiang et al. 1997). Functional
ceramics and glasses are extensively used in the production of electric, electronic, magnetic and optical
components for high performance systems such as transducers, resonators, actuators and sensors. The past
decades have seen a tremendous resurgence in the use of advancedceramics in structural applications such as
roller and sliding bearings, adiabatic diesel engines, cutting tools, etc. Conventional forming and sintering

processes of ceramic powders do not necessarily give the high dimensional accuracy and the good surface
quality required for functional and structural components. Thus, precision machining technologies have been
developed for the manufacture of cost-effective and quality-assured precision parts produced by brittle and
hard solids.
Abrasive jet machining offers a solution to the expanding need for machining brittle materials such as single
crystals, glasses and polycrystalline ceramics, and for increasing complex operations to provide intricate
shapes and work piece profiles.
This machining process is non-thermal, non-chemical, creates no change in the microstructure, chemical or
physical properties of the work piece and offers virtually stress-free machined surfaces. It is therefore used
extensively in machining hard and brittle materials that are difficult to cut by other conventional methods.
The abrasive jet machining parameters affecting the machining response are studied and some of the key
parameters are selected for an experimental evaluation of their effect on machining performance parameters
material removal rate, taper and overcut while machining alumina ceramic.
THE MAIN OBJECTIVES OF THIS WORK ARE AS FOLLOWS:

1. To investigate experimentally the effect of process parameters like pressure, abrasive mesh size,
standoff distance and work piece material thickness on the material removal rate, taper and overcut in
drilling of alumina ceramic.
2. To analyze the effect of these parameters on the material removal rate and dimensional accuracy in
terms of radial overcut and taper.
ABRASIVE JET MACHINING METHODOLOGY:

The process flow chart for abrasive jet machining process:
Table 3: Abrasive Machine Parameters

CHAPTER 3
DESIGN OF COMPONENTS
AIR COMPRESSORS:
History And Its Classification
The first air compressor was human lungs; by blowing on cinders man started his fires. Then with birth of
metallurgy man began to melt metal and high temperatures were needed. A more powerful compressor was
required.
One of the earliest recorded uses of compressed gas (air) dates back to 3rd century B.C. This carly use of
compressed air was the "water organ." The invention of the "water organ" is commonly credited to Cresibius
of Alexandria. Ctesibius also developed the positive displacement cylinder and piston to move water. The
water organ consisted of a water pump, a chamber partly filled with air and water, a row of pipes on top
(organ pipes) of various diameters and lengths plus connecting tubing and valves. By pumping water into the
water/air chamber the air becomes compressed. This concept was further improved by Hero of Alexandria
(also noted for describing the principles of expanding steam to convert steam power to shaft power). The
first mechanical compressor, the hand-operated bellows, emerged in 1500 B.C. In the 1850s, while trying to
find a replacement for the water wheel at their family's woollen mill, Philander and Francis Roots devised
what has come to be known as the Roots blower. Their design consisted of a pair of figure-eight impellers
rotating in opposite directions. While some Europeans were simultaneously experimenting with this design,
the Roots brothers perfected the design and put it into large-scale production.
In 1808 John Dumbbell envisioned a multi-stage axial compressor; unfortunately his idea consisted only of
moving blades without stationary airfoils to turn the flow into each succeeding stage. Not until 1872 did Dr.
Franz Stolze combine the ideas of John Barber and John Dumball to develop the first axial compressor
driven by an axial turbine. Due to a lack of funds, he did not build his machine until 1900. Dr. Stolze's
design consisted of a multi-stage axial flow compressor, a single combustion chamber, a multistage axial
turbine, and a regenerator utilizing exhaust gases to heat the compressor discharge gas.
A Compressor is a machine that compresses the air or another type of gas from a low inlet pressure (usually
atmospheric pressure) to a higher desired pressure level. Compressor increases the pressure of the air by
reducing its volume. Work required for increasing pressure of air is available from the prime mover driving
the compressor. Generally, electric motor. Internal combustion engine or steam engine, turbine etc. are used
as prime movers. Compressors are similar to fans and blowers but differ in terms of pressure ratios. Fan is
said to have pressure ratio up to 1.1 and blowers have pressure ratio between 1.1 to 4 while compressors
have pressure ratios more than 4.

Compressors can be classified in the following different ways.
(a) Based on principle of operation: Based on the principle of operation compressors can be classified
as.
i). Positive displacement compressor.
ii). Non-positive displacement compressors
In positive displacement compressors the compression is realized by displacement of solid boundary and
preventing fluid by solid boundary from flowing back in the direction of pressure gradient. Due to solid wall
displacement these are capable of providing quite large pressure ratios. Positive displacement compressors
can be further classified based on the type of mechanism used for compression. These can be
(i) Reciprocating type positive displacement compressors
(ii) Rotary type positive displacement compressors.
Reciprocating compressors generally, employ piston-cylinder arrangement where displacement of piston in

cylinder causes rise in pressure. Reciprocating compressors are capable of giving large pressure ratios but
the mass handling capacity is limited or small. Reciprocating compressors may also be single acting
compressor or double acting compressor. Single acting compressor has one delivery stroke per revolution
while in double acting there are two delivery strokes per revolution of crank shaft. Rotary compressors
employing positive displacement have a rotary part whose boundary causes positive displacement of fluid
and thereby compression. Rotary compressors of this type are available in the names as given below;
(i) Roots blower
(ii) Vane type compressors
Rotary compressors of above type are capable of running at higher speed and can handle large mass flow
rate than reciprocating compressors of positive displacement type.
Non-positive displacement compressors also called as steady flow compressors use dynamic action of solid
boundary for realizing pressure rise. Here fluid is not contained in definite volume and subsequent volume
reduction does not occur as in case of positive displacement compressors. Non-positive displacement
compressor may be of axial flow type" or centrifugal type" depending upon type of flow in compressor.
(b) Based on number of stages: Compressors may also be classified on the basis of number of stages.
Generally, the number of stages depends upon the maximum delivery pressure, Compressors can be single
stage or multistage. Normally maximum compression ratio of 5 is realized in single stage compressors. For
compression ratio more than 5 the multistage compressors are used.

Type values of maximum delivery pressures generally available from different type of compressor are,
(1) Single stage Compressor, for delivery pressure up to 5 bar.
(ii) Two stage Compressor, for delivery pressure between 5 to 35 bars.
(ii) Three stage Compressor, for delivery pressure between 35 to 85 bars.
(iv) Four stage compressor, for delivery pressure more than 85 bars.
(c) Based on Capacity of compressors: Compressors can also be classified depending upon the capacity of
Compressor or air delivered per unit time. Typical values of capacity for different compressors are given as;
(i) Low capacity compressors, having air delivery capacity of 0.15 m³/s or less
(ii) Medium capacity compressors, having air delivery capacity between 0.15 to 5 m³/s.
(iii) High capacity compressors, having air delivery capacity more than 5 m³/s.
(d) Based on highest pressure developed: Depending upon the maximum pressure available from
compressor they can be classified as low pressure, medium pressure, high pressure and super high pressure
compressors. Typical values of maximum pressure developed for different compressors are as under:
(i) Low pressure compressor, having maximum pressure up to 1 bar.
(ii) Medium pressure compressor, having maximum pressure from bar to 8 bar
(iii) High pressure compressor, having maximum pressure from 8 to 10 bar
(iv) Super high pressure compressor, having maximum pressure more than 10 bar.
Air compressors are generally positive displacement units and either of reciprocating piston type or the
rotary screw or rotary vane types. These three types are explained in detail.
Reciprocating Compressors
Reciprocating compressors have been the most widely used for industrial plant air systems. The stage
compressors. The Single acting cylinder performs compression on one side of the piston two major types are
single acting and double acting, both of which are available as one or two during one direction of the power
stroke. Two stage compressions reach the final output pressure in two compression cycles, or stages, in
series.
The double acting compressor is configured to provide a compression stroke as the piston moves in either
direction. This is accomplished by mounting a cross head on the crank arm which is then connected to a
double acting piston by a piston rod distance pieces connect the cylinder to the crankcase. They are sealed to
prevent mixing of crank shaft lubricant with the air, but vented so as to prevent pressure built up.

Piston Compressors
Piston type compressors are the oldest and most commonly used compressor in the pneumatic industry
because of its flexibility, high pressure capability, ability to rapidly dissipate heat of compression and oil
free. They are built for either stationary or portable services.
A. Single Cylinder Compressor
Piston compressors are available as single or double acting, oil lubricated or oil free with different number of
cylinders in different configurations. With the exception of really small compressors with vertical cylinders,
the V configuration is the most common for small compressors. On double acting, large compressors the L
type with vertical low pressure cylinder and horizontal high pressure cylinder, offer immense benefits and is
why this the most common design. The construction and working of a piston type reciprocating compressor
is very much similar to that of an internal combustion engine.
1. Construction: Piston type compressor consists of cylinder, cylinder head, and piston with piston
rings, inlet and outlet spring loaded valves, connecting rod, crank crankshaft and bearings.
2. Operation: Compression is accomplished by the reciprocating movement of a piston within a
cylinder. This motion alternately fills the cylinder and then compresses the air. A connecting rod transforms
the rotary motion of the crankshaft into the reciprocating motion of piston in the cylinder. Depending on the
application, the rotating crank (or eccentric) is driven at constant speed by suitable prime mover (usually
electric motor).
3. Inlet stroke: suction or inlet stroke begins with a piston at the top dead centre (a position providing a
minimum or clearance volume). During the downward stroke, piston motion reduces the pressure inside the
cylinder below the atmospheric pressure. The inlet valve then opens against the pressures of its spring and
allows air to flow into the cylinder. The air is drawn into the cylinder until the piston reaches a maximum
volume position (bottom dead centre). The discharge valve remains closed during this stroke
4. Outlet stroke: During compression stroke piston moves in the opposite direction (Bottom dead
centre to top dead centre), decreasing the volume of the air. As the piston starts moving upwards, the inlet
valve is closed and pressure starts to increase continuously until the pressure inside the cylinder is above the
pressure of the delivery side which is connected to the receiver. Then the outlet valve opens and air is
delivered during the remaining upward motion of the piston to the receiver

Fig 7: Single Stage Compressor
B. ANALYSIS OF SINGLE CYLINDER SINGLE STAGE AIR COMPRESSOR
A typical indicator diagram for reciprocating compressor with three different types of compression is shown
in the Figure. Clearance volume is neglected.
Fig 8: Types of Compression.
Constant pressure line 4-1 represents the suction stroke. The air is then compressed adiabatically (Process
line 12",) and is then forced out of the cylinder at constant pressure (process 23). Area 12"34 represents the
work. If the compression is carried out isothermally, then it follows the curve 12" which has less slope than
both isentropic and polytrophic processes. This work done that is area 12"34 in isothermal process is
considerably less than that due to adiabatic compression. Thus compressor will have higher efficiency if
compression follows isothermal process. It is not possible in practice as to achieve isothermal process, as the
compressor must run very slowly. In practice compressors run at high speeds which results in polytropic
process. The cold water spray and multistage compression are used for approximating to isothermal
compression while still running the compressor at high speeds.

C. WORKDONE IN A SINGLE STAGE COMPRESSOR NEGLECTING CLEARANCE:
Figure shows the PV diagram of the air in the cylinder of an air compressor. Constant pressure line ab
represents the suction stroke. The air is then compressed adiabatically (process line bc,) and is then forced
out of the cylinder at constant pressure (process cd). Area abcd represents the work .
Fig 9: P V Diagram.
D. WORK DONE IN A SINGLE STAGE COMPRESSOR CONSIDERING CLEARANCE
In practical design of compressors, some clearance is required between the cylinder and piston to prevent
hitting of piston to crown of the cylinder. Figure shows a PV diagram of single stage compressor with
clearance.
Fig 10: PV Diagram with Clearance
Thus when the compressed air is delivered during the delivery stroke, some amount of air corresponding to
clearance volume V3 at a pressure P₂ will be left over in the cylinder. During the next suction stroke this air
expands back to initial pressure p1 and volume V4. Thus before the fresh air enters the cylinder some air
corresponding to volume V4 will be already there in the cylinder. This volume inhaled during the suction

stroke will be V1 –V4 which is less the swept volume Vs.
The work done on the air delivered is not affected by the clearance volume as the work required to compress
the clearance volume is theoretically regained during its expansion from V3-V4, Thus the work done is given
by
Work done during compression (V1-V4)
E. Volumetric efficiency
Free air delivery It is the amount of atmospheric air that can be sucked by the compressor at suction or inlet
condition of compressor at one atmospheric pressure, 20 °C. 100 percent dry air and compressor motor
running at 100 % of the rated value. FAD is an important purchasing parameter and it measures the capacity
of a compressor in terms of air flow it can handle. FAD is used to compare different compressors. It is
important to note that induced mass per cycle must equal the delivered mass per cycle as per law of
conservation of mass, although the induced and delivered volumes will be different.
Actual volume of air taken referred to free air conditions

Swept volume of the compressor
Where k= (Vc/Vs) = clearance ratio

Subscript "a" refers to free air or ambient conditions and subscript "1" refers to the condition before
compression.

The compressor used in our project has following specifications:
Type Reciprocating compressor
Power 1.5/2 HP
Volume 30/50litre
Velocity 2800 rpm
Pressure 150 psi
Table 4: Reciprocating Compressor Specifications
Fig 11: Air Compressor

FRL Unit
The FRL Unit (Air Filter Regulator Lubricator unit) which is otherwise called the moisture separator or
dehumidifier is required for separating the moisture from air. Atmospheric air always contains some water
vapour in it. As the air with high velocity is blown from the nozzle there is an abrupt rise in pressure which
converts water vapour into moisture. The moisture makes the abrasive particles to agglomerate and this clogs
Fig 12: FRL (Air Filter)

The outlet of the Nozzle. To avoid this clogging moisture separator should be used before abrasive particles
are mixed with compressed air. Different FRL units are available commercially.
The Vibrating Unit
Vibrating Unit is used for mixing the air with the abrasive particles. The Abrasive particles are stored in a
container through which air is flown. The particles are agitated by means of a cam and motor arrangement.
The rotation of cam results in vibration in the abrasive container. The flow rate of abrasive materials can be
controlled by manipulating the rotational speed of the motor. The abrasive container will have one inlet and
one outlet for air passage and will be vertically suspended from a hinged joint.
So the Vibrating Unit consists of following parts-
1) Vibrating arm
2) Abrasive container
1) Vibrating Arm
Vibratory arm is fixed with shaft of the induction motor. The profile of the vibratory arm is taken tobe a
rectangular one. When the motor rotates; it makes the container to vibrate. Width of vibratory arm is 20 cm.
2) Abrasive Container (mixer)
Abrasive container is fabricated by a hollow cylindrical thick metallic pipe of 60mm diameter and 140mm
height. Two circular pipes of internal diameter 18mm is dipped from the top and welded, which would act
as input for compressed air and output for mixture of compressed air and abrasive particles. The length of
input pipe dipped is kept long to uniform circulation of compressed air into the container.
Fig 13: Vibrating Unit Fig 14: Mixing Chamber
Induction Motor
Induction motor used in this project is Single phase AC Induction motor of 0.5 watt. This motor is used
to provide rotational motion to the vibratory arm attached with it. The installed induction motor has
speedof 600 rpm

Fig 15: Induction Motor
Nozzle
A standard high carbon high chromium cylindrical rod was cut into required length by power hack-saw.
The external diameter was then brought to 20mm by turning it in lathe and then the tip was made by
tapering one end by the same lathe. A blind hole of approximate depth 25mm was made on the planner face
of the rod by means of a 12mm drill bit in a drilling machine. The end of the blind hole forms a shapeof 118
degree taper because of the tool tip angle. Internal threading was made by 12mmtap. Then the tip of the
nozzle is diameter drilled to approximate diameter of 1mm.
Fig 16: Nozzle
CNC (guide mechanism)

Computer Numerical control (CNC) is used to rotate the machine tools that are operated by precisely
programmed commands coded on a storage medium, as opposed to controlled manually via levers, or
mechanically automated via cams alone. The position of the tool is driven by motors through a series of
pulleys in order to provide highly accurate movements, in our design, direct-drive stepper motors have

been used to drive both the axis. The X-Axis holds the workspace for the work piece to be set. Y-Axis holds
the space for the gantry plate wherein the nozzle is fixed. The CNC works through a computer system
using G-code. And the whole assembly is mounted on the work table.
Fig 17: CNC Machine

Machining Chamber
It is cubical in shape. It is basically made up of transparent plastic structure. The entire structure is closedso
as to prevent the abrasives from spreading around. It houses the CNC-Nozzle assembly. The used abrasives
are to be removed by opening the bottom glass of the working chamber. One of the sides is closed in such a
way that it can be removed by removing the threaded bolt. It is done so to load and unloadthe workpiece
Fig 18: Machining Chamber
Fabrication And Assembly

1. Abrasive Container: The abrasive container was made out of a hollow cylinder. Two iron plates
were welded on both ends of the container. On the top plate two holes were drilled and iron pipes were fitted
with these holes. The inlet iron pipe is longer so as to make more agitation of the abrasive particles. The
outlet pipe is shorter. Both the pipes are clamped with nylon pipes which carries air through them. After
removal of moisture by the FRL unit the compressed air goes to abrasive container through inlet, mixes with
abrasive particle and then the air with abrasive particles moves through the nozzle to perform the machining

action.
Fig 19: Abrasive Container
2. THE VIBRATOR ASSEMBLY: The angle section was welded with base plate by are welding. A
rod was welded with angle orienting it parallel with the base plate. An induction motor was placed on the
base plate by tightening with nut bolt. Cam was fixed with the motor shaft. Then abrasive container was
connected to the rod by means of the holder. The container is free to rotate around the rod.
Fig 20: The Vibrator Assembly

ABRASIVES AND THERE SPECIFICATIONS
Abrasives
An abrasive is a material used to cutting, drilling, finishing or shaping operations. In this project we use
abrasive for drilling and cutting operations. The different abrasive can be used according to operation to be
performed.
(a) Glass beads
Glass is a material that can be found anywhere and is widely used in our everyday life. Glass can be easily
sourced as it is made from silicon, the second most common element on earth [6]. It exists in the form of
containers, such as bottles, food container jars, cosmetics and other products; or to be used in the industries
for construction or manufacturing of electronics, automation, etc.
The recycled glass is processed into crushed glass for various uses depending on its coarseness. One of the
usable end products is crushed glass abrasive. It has been recommended as alternative abrasive media due to
it environmentally friendly features, generates less dust while performing higher cleaning rate.
Glass bead abrasive is available in various sizes, which are selected according to the requirements. Larger
beads create larger impacts and remove more surface material when extreme cleaning or peening is required.
Smaller beads are used for lighter work that requires a very smooth surface finish.
Glass bead abrasive has several advantages over other media:
1. The glass beads are inert.
2. Unlike steel shot or grit, one does not need to worry about residual iron that will rust.
3. Glass bead abrasive can be readily recycled and reused many times.
Fig 21: Glass Beads

(b) Walnut Shell:
Walnut Shell abrasive is a fibrous product made from crushed walnut shell. It is the most common type of
soft abrasive for industrial use.
Walnut shell is used as an abrasive blast media similar to sand for cleaning, but without the negativities
associated with other abrasive materials. Because walnut shell blasting is a gentle, non-corrosive
environmentally friendly method of removing foreign matter, coatings, paint, dirt, grime, mold and smoke
residue from almost any surface including metal, wood, aluminum, brass, stone, glass, fiberglass, plastic,
masonry and tile without scratching, etching, pitting the substrate material / underlying surface or marring
cleaned areas. When used as a blasting media, walnut shell grit is extremely durable, angular and multi-
faceted, yet is considered a ‘soft abrasive’. Walnut shell blasting media is also great for rust free paint
removal from sheet metal and for cleaning engines, steam turbines and transmissions. Walnut shell blasting
grit is an excellent replacement for sand (free silica) to avoid inhalation health concerns.
(c) Crushed Bones
Fig 22: Walnut Powder
Abrasive particles draw their applications as such from their intrinsic physical properties. These latters
include hardness, resilience, density, structural geometry and other factors. For example, bones from animals
having an average hardness of 5 on the moh scale but are less resilient than aluminum oxide, or corundum.
The chemical composition of bones is basically a mixture of calcium phosphate, calcium carbonate, calcium
fluoride and magnesium phosphate. Once exposed to heat above 250 degrees celcius, a bone loses its water
content, and its initial cristalline structure is therefore altered. This latter is even more altered after crushing
and grinding. However, its average harness is high enough to be used as an abrasive media, thus,
representing a part of this claimed invention, namely the use of such material for application as an abrasive
material.

Fig 23: Crushed Bones
Abrasive Grain Size Application
Glass Beads 30,35 microns Good For Cutting And

Deburring
Walnut Shells 35,45 microns Good For etching
Bones 40,50 microns Good For Blasting
Table 5: Abrasives Used

(d) Desired properties of abrasives used in AJM
1. Abrasives should have sharp and irregular shape.
2 It should be fine enough to remain suspended in the carrier gas.
3. In addition to hardness, the important properties of an abrasive is friability. Friability is the ability of
abrasive grains to fracture into smaller pieces; this property gives abrasives self-sharpening characteristic.
High friability indicates low strength or low fracture resistance of the abrasives. High friable abrasives
fragment more rapidly than lower friable abrasives.
4. Should be cheap and easily available.
5. It should have excellent flow characteristics.
(e) Reuse of Abrasives is Not Recommended Because:
1. Cutting capacity decreases after first use.
2. Contamination clogs the small orifices in the nozzle.

CHAPTER 4
DESIGN EXPERIMENT
SELECTION OF CONTROL VARIABLES
Major AJM variables that control material removal rate, taper cut and radial over cut are air pressure,
mixing ration of air- abrasive particle, stand of distance, nozzle diameter, work piece thickness and
abrasive size.
1. Air Pressure: As shown in graph as the air pressure increases the material removal rate increases.
Fig 24: Representation of Various Graphs
2. Mixing Ratio: The mixing ratio of air and abrasive particle also effect the material removal rate
as the mixing ration increases the material removal rate increases and up to maximum point than
after the increase in mixing ratio will decrease the material removal rate as shown in figure.
3. Stand of Distance: In starting phase, the stand of distance decreases the material removal rate
than aster increase in stand of distance increase the material removal rate after reaching at the
highest point the increase in the stand of distance will decreases the material removal rate.
Fig 25: Effect of SOD

4. Abrasive Size: Abrasive size is the affecting factor on material removal rate as the size of
Abrasive increases it gives rough surface drill and if the size of abrasive decreases it gives high
accurate hole dimension.
5. Metal Removal Rate: Effect of mixing ratio on MRR
Increased mass flow rate of abrasive will result in a decreased velocity of fluid and will thereby
the available energy for erosion and ultimately the MRR. It is convenient to explain this fact by
term mixing ratio.
The material removal rate can be improved by increasing the abrasive flow rate provided the
mixing ratio Volume flow rate of carrier gas per unit time is kept constant. The mixing ratio is
unchanged only by simultaneous increase of both gas and abrasive flow rate. An optimum value
of mixing ratio that gives maximum MRR is predicted by trial and error. In place of mixing
ratio, the mass ratio "a" may be easier to determine.
Metal Removal Rate Formula
Where,
U- Velocity of abrasive jet at the point of impact.
H- Flow strength or hardness of the work material.
Mg- Mass flow rate of abrasive particles.
𝜌g - Density of each abrasive particle.

a) Variable Related to Abrasive Particle Size

There are number of abrasives available in market. Here we are using fully home based, less costly
and easily available abrasives like glass beads, crushed walnut shells and crushed animal bones of
different sizes respectively.
Table 6: Converging Table
b) Variable related to machining process

Air pressure, Stand of Distance and Abrasive particle size are the major process variables affecting
the performance of Abrasive jet machine. The Abrasive jet machine has a fixed air and abrasive
mixing chamber which vibrates with the predefined frequency. So air pressure, stand of distance and
particle size are selected as the control parameters and frequency will be our confounding parameter.
Suitable level of pressure, stand of distance and particle size will be selected.
c) variable related to machined part
The type of material, its thickness, shape and size of cut are the major work related variable affecting
Abrasive jet machine. The work materials are selected as wood, acrylic, GI sheets, and ceramics etc.

SELECTION OF RESPONSE VARIABLES

The most important measure of any material removal process are material removal rate (MRR) and
Accuracy. Non-convention processes like abrasive jet machining involve an overcut and taper
associated with machining due to the character of the process. Hence the parameter selected to be
measure as representative of the process response are
1. Material removal rate (MRR)
2. over cut
3. Tape
EXPERIMENTAL PROCEDURE
The detailed procedure followed for abrasive jet drilling is described as under
1. Measure the weight of the work piece.
2. Add the abrasive powder in the mixing chamber of the abrasive jet machine
3. Adjust the desired pressure level in the abrasive jet machine by pressure regulating valve.
4. Adjust the Desire SOD according to its level.
5. Adjust the fixture and make suitable arrangement to fix the work piece in the work piece holder.
6. Turn on air compressor to maintain desire pressure level in the abrasive jet machine.
7. Turn on the machine, stopwatch and wait until the machining is done.
8. After machining, clean the plate and weight the plate in weight scale and record the result for
calculating material removal rate.
9. Repeat the above all steps for next run for experimentation.

CHAPTER 5
RESULTS



CHAPTER 6
Conclusion
It was shown that AJM process is receiving more and more attention in the machining areas, particularly for
the processing of difficult-to-cut materials. Its unique advantages over other conventional and un-
conventional methods make it a new choice in the machining industry. It is concluded that wide
experimental investigations are required to fully understand the relationship between important AJM
parameters, namely Air pressure, nozzle size and shape, abrasive mass flow rates and process output in
greater detail for aluminium, brass, cast iron, ceramics, copper, composites, granite, mild steel, stainless steel
and titanium as the right choice of process parameters is very important for good cutting performance. There
is much scope of research in the AIM which can be performed by changing the nozzle design, pressure,
angle, SOD, etc. and Comparing the effect of various parameters on MRR on different metals like super
alloys, composites, glass, and ceramics, by improving the cylindricity of the hole.
In this project a complete design of the Abrasive Jet Machine is given. The CNC module IS designed taking
in account of currently available components in the market. The designing and assembling of a very large
number of components was a tremendous task and was completed on time. However because some parts
couldn't be purchased the whole assembly was limited to the resulting operations. The project can go beyond
its current position and capabilities by employing more abrasives into it.
Thus can be done by using some other abrasives like ginger powder, crushed brick powder, crushed date
seeds, crushed walnut powder, etc.

REFERENCES
[1] Bhavin C. Mistry, Mr.Vikram V. Patel, 3 Pravin K Trivedi "EXPERIMENTAL ANALYSIS OF
VARIOUS PARAMETERS OF AJM PROCESS ON ALUMINA CERAMIC MATERIAL" IJCRT
Volume 9, Issue 1 January 2021
[2] Bhaskar Chandra Kandpal, Naveen Kumar, Rahul Kumar, Rahul Sharma, Sagar Deswal "
MACHINING OF GLASS WITH ALUMINA AND IN ABRASIVE JET MACHINING" International
Journal of Advanced Engineering Technology, E-ISSN 0976-3945
[3] K Prashanth, D H Pachchinavar "Fabrication of Abrasive Jet Machine" International Journal of
Scientific Research & Engineering Trends, Volume 6, Issue 4, July-Aug-2020
[4] Dr.Madhu.S" NOZZLE DESIGN AND MATERIAL IN ABRASIVE JET MACHINING PROCESS-
A REVIEW" International Journal of Applied Engineering Research, Vol. 10, No.33, 2015

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DESIGN AND FABRICATION OF

ABRASIVE JET MACHINE

Under the guidance of

ER. SUHAIL SHAHZAD

In partial fulfillment for the award of the

SSM COLLEGE OF ENGINEERING

PARIHASPORA, PATTAN, BARAMULLA KAHSMIR

(AFFILIATED TO UNIVERSITY OF KASHMIR)

DESIGN AND FABRICATION OF ABRASIVE JET MACHINE

Signature of the Student

DEPARTMENT OF MECHANICAL ENGINEERING ii

DESIGN AND FABRICATION OF ABRASIVE JET MACHINE

This is to certify that the project entitled

DESIGN AND FABRICATION OF ABRASIVE JET MACHINE

YAWER NABI BHAT 19204135025

Mr. Mohammad Nayeem Dr. Sajaad Hussain

Department of Mechanical Engineeing

Er. Suhail Shahzad

Department of Mechanical Engineering

DEPARTMENT OF MECHANICAL ENGINEERING iii

DESIGN AND FABRICATION OF ABRASIVE JET MACHINE

DEPARTMENT OF MECHANICAL ENGINEERING iv

DESIGN AND FABRICATION OF ABRASIVE JET MACHINE

DEPARTMENT OF MECHANICAL ENGINEERING v

CHAPTER 2 – LITERATURE SURVEY

Existing system 10-12

CHAPTER 3 – DESIGN OF COMPONENTS

Air compressor 14-21

DEPARTMENT OF MECHANICAL ENGINEERING vi

Piston Compressors 17-21

CHAPTER 4 - DESIGN EXPERIMENTS

Selection of control variables 30-32

Selection of response variables 33

CHAPTER 5 – RESULTS 34-36

DEPARTMENT OF MECHANICAL ENGINEERING vii

Fig. 1 Principle of AJM

Fig. 2 schematic diagram of AJM

Fig. 3 Effect of Abrasive Flow Rate on MRR

Fig. 4 Effect of Exit Gas Velocity and Abrasive Particle Density

Fig. 5 Effect of nozzle pressure on MRR

Fig. 6 Effect of SOD on Machined Profile

Fig. 7 Single Stage Compressor

Fig. 8 Types of Compression

Fig. 10 PV Diagram with Clearance

Fig 15: Induction Motor

Fig 17: CNC Machine

Fig 18: Machining Chamber

Fig 19: Abrasive Container

Fig 20: The Vibrator Assembly

Fig 22: Walnut Powder

Fig 23: Crushed Bones

DEPARTMENT OF MECHANICAL ENGINEERING viii

DEPARTMENT OF MECHANICAL ENGINEERING ix

DEPARTMENT OF MECHANICAL ENGINEERING 1

other generally neutral gas plus abrasive materials.

Fig 1: Principle of AJM

DEPARTMENT OF MECHANICAL ENGINEERING 2

Fig 2: Schematic Layout of AJM

3. Size of abrasive grain

4. Velocity of abrasive jet

5. Flow rate of abrasive

7. Geometry, composition and material of nozzle

DEPARTMENT OF MECHANICAL ENGINEERING 3