Abrasive Jet Machining

Working Principles – equipment used – Process

parameters – MRR-Variation in techniques used – Applications
Working Principle

• A stream of abrasive grains (Al2O3 or SiC) is carried by high pressure gas or air
(compressed).
• Impinges on the work surface at very high velocity through a nozzle of 0.3 to
0.5 mm diameter
• Sand Blasting (SB) - a similar process
• The major differences between are SB and AJM
– smaller diameter abrasives
– a more finely controlled delivery system
• Material removal – by mechanical abrasion action of the high velocity abrasive
particles
 Process parameters
Material removal rate depends on the following parameters
1. Mass flow rate
2. Abrasive grain size
3. Gas pressure
4. Velocity of the abrasive particles
5. Mixing ratio
6. Stand off distance (Nozzle tip clearance)
 Process parameters
1. Mass Flow Rate 2. Abrasive grain size

• MRR increases with increasing MFR

• Larger sizes are used for rapid MRR
• After reaching an optimum value, MRR
• Smaller sizes are used for surface finish and
decreases since MFR of gas decreases with
precision.
increasing abrasive flow rate.
 Process parameters
3. Gas Pressure 4. Velocity of abrasive particles

• MRR increases with increasing air or gas

• MRR increases with increasing velocity of
pressure.
abrasive particle.
 Process parameters
5. Mixing Ratio 6. Stand-off Distance

• It is the ratio of mass flow rate of abrasive to

• MRR first increases with the increase of tip
mass flow rate of gas.
clearance from workpiece up to certain limit
• MRR increases with increase of mixing ratio
after that it remains unchanged then
up to certain point after that it decreases.
decreases.
Water Jet Machining
Working Principle
• When a small diameter jet of water with a high velocity strikes the work piece material it erodes
the material from the surface. (Water jet as cutting tool)

• Water is pumped at a sufficiently high pressure, 200-400 MPa (2000-4000 bar) using intensifier
technology.

• An intensifier works on the simple principle of pressure amplification using hydraulic cylinders of
different cross-sections.

• When water at such pressure is issued through a suitable orifice (generally of 0.2- 0.4 mm dia),
the potential energy of water is converted into kinetic energy, yielding a high velocity jet
(1000 m/s).
Elements of Water jet machining
• It is consists of
(i) Pumping unit (oil pump)
(ii) Intensifier
(iii) Accumulator
(iv) Nozzle
(v) Drainer /Catcher
 Rigid high pressure tubing
Pressure vessel to store water pressure
To minimize pulsation during operation

(250-500 hours)
Oil pump run by electric motor
1000 m/s

To produce high pressure water(40 times of

oil pressure) Pw=(Po X A o)/Aw
2000-4000 bar
Catcher/
Absorb residual energy of water-to reduce the noise
Process Parameters
1. Water pressure (2000-4000 bar)
2. Diameter of the nozzle (0.2- 0.4 mm dia)
3. Traverse speed (Low traverse speed to cut thick material)
4. Stand off distance (3 - 25 mm)
Advantages of water jet machining
There is no heat generated in water jet cutting; which is especially useful
for cutting tool steel and other metals where excessive heat may change
the properties of the material.

 Unlike machining or grinding, water jet cutting does not produce any
dust or particles that are harmful if inhaled.
Disadvantages of water jet machining
 One of the main disadvantages of water jet cutting is that a limited
number of materials can be cut economically.
 Very thick parts cannot be cut by this process economically.
 Taper is a problem with water jet cutting in very thick materials and
cause dimensional inaccuracy.
Applications Of WJM Process
• Water jet cutting is mostly used to cut lower strength materials such as
wood, plastics and aluminum.

• When abrasives are added, (abrasive water jet cutting) stronger materials
such as steel and tool steel can be cut.
Abrasive Water Jet Machining
Abrasive Water Jet Machining
• Abrasive water jet machining is a mechanical energy based material removal
process in which abrasives are mixed with water to form the abrasive slurry.
• This process is similar to abrasive jet machining except that the water is used
as carrier medium instead of dry air.
• In this process a high stream of abrasive jet particles are mixed with
pressurized water & injected through the nozzle on the work piece.
• Basic mechanism : Erosion or chipping action.
• This process can be used for cutting, drilling and cleaning of hard materials.
• The materials which are electrically non conductive and difficult to machine
can be easily cut more rapidly and effectively.
 Elements of abrasive water jet machining
1. Pumping system -
To produce and supply high pressure water to the mixing chamber (similar to WJM)
2. Abrasive feed system-
To supply abrasive particles to the nozzle. Flow rate of abrasives can be controlled by changing the
diameter of the control orifice
Two types of feed system:
i. Mixing at the nozzle-Stream of dry abrasives delivery to the nozzle where it
mixes with water jet.
ii. Mixing before entry of nozzle - Direct supply of slurry (mixture of water and abrasive) to the nozzle.
Desired velocity of slurry - 700 m/s
3. Abrasive water jet nozzle
i. To Mix the abrasive particle with water
ii. To produce high velocity abrasive water jet.
Pressure head is converted into velocity head by high pressure water to small dia(0.2 to 0.4 mm)
orifice
4. Catcher (replaceable inserts to break the jet)
To absorb and dissipate the residual energy of the water.
 (Sapphire , tungsten
carbide, boron carbide)

(To absorb and dissipate the residual energy of

the water)
TYPES OF NOZZLE
Single jet, side feed nozzle
• Abrasives are fed from the side and mix with water in
mixing chamber.
• Least expensive but not provide an optimum mixing
efficiency.
• Nozzle subjected to rapid wear.

Multi jet central feed nozzle

• Abrasives are centrally fed surrounded by multiple
water jet.
• Better mixing of abrasives with the water jet.
• Fabrication of nozzle is difficult and expensive.
• Longer life.
 Process parameters
Material removal rate depends on the following parameters

Water: Pressure, flow rate

Abrasives: type, size and flow rate
Cutting parameters: Feed rate and stand –off-distance
 PRINCIPLE OF USM
• A slurry of small abrasive particles are forced
against the workpiece by means of a vibrating tool
and it causes the removal of metal from the
workpiece in the form of extremely small chips.
• One kind of grinding method. (ultrasonic grinding
or impact grinding)
• To machine hard and brittle materials like
carbides, glass, ceramics, silicon, germanium,
titanium, tungsten, tool steels, die steels etc.,
• Ultrasonic – High frequency sound waves
above audible range
audible range for human ear20 Hz to 20 kHz
Below audible range -Infrasonic
CONSTRUCTION AND WORKING
• Generator: Ultrasonic oscillator and
amplifier is known as generator. Used to
convert applied electrical energy at low
frequency to high frequency.
 Transducer- Magnetostrictive material (

(To convert low frequency to

high frequency electrical energy)
Working Principle