PRODUCTS

MANUFACTURED BY AJM ,
WJM.
Branch – mechanical.
 INTRODUCTION-

 Water Jet Machining (WJM) and Abrasive Jet Machining

(AJM) are two non-traditional or non-conventional machining
processes. They belong to mechanical group of non-
conventional processes like Ultrasonic Machining (USM) and
Abrasive Water Jet Machining (AWJM). In these processes
(WJM and AJM), the mechanical energy of water and abrasive
phases are used to achieve material removal or machining.
ABRASIVE JET MACHINING(AJM)-
 The process consist of mixture of fine abrasive particles, usually about 0.025
mm in diameter and gas at high pressure.
 This stream of mixture is directed

through a nozzle on to the surface of

the work piece.
 The abrasive particles impinge on

the work piece at high speed.

 As the particles impacts the surface,

it causes a small fracture of the work

surface which result in removal of metal.
 The gas stream carries both the

abrasive particles and the fractured

(wear) particles way.
PROCESS SETUP-
 PROCESS PARAMETER OF AJM-
Abrasives
a) material – Al2O3 SiC Glass beads
Crushed glass Sodium bi
carbonate b) shape –
irregular/regular
c) Size – 10 to 50 microns
d) Mass flow – 2-20 gm/min
Carrier Gas
a) Composition – Air, CO2, N2
b) Density – 1.3 kg/m3
c) Velocity - 500 to 700 m/s
d) Pressure - 2 to 10 bar
e) Flow rate - 5 to 30 microns
Abrasive Jet
b) Velocity - 100 to 300 m/s
c) Mixing ratio – Volume flow rate
of abrasives/Volume flow rate of
gas
d) Stand off distance – SOD- 0.5 to
15mm.
e) Impingement angle – 60 to 90 deg
Nozzle
a) Material – WC/Sapphire
b) Diameter – 0.2 to 0.8 mm
c) Life – 300 hours for sapphire, 20
to 30 hours for WC
 APPLICATIONS-
 This is used for abrading and frosting glass more economically as
compared to etching or grinding
 Cleaning of metallic smears on ceramics, oxides on metals, resistive
coating etc.
 Used for cutting thin fragile components like germanium, silicon etc.
 Register treaming can be done very easily and micro module fabrication for
electrical contact , semiconductor processing can also be done effectively.
 Used for drilling , cutting , deburring etching and polishing of hard and
brittle materials.
 Most suitable for machining brittle and heat sensitive materials like glass,
quartz, sapphire , mica , ceramics germanium , silicon and gallium. 9. It is
also good method for deburring small hole like in hypodermic needles and
for small milled slots in hard metallic components.
PRODUCT MANUFACTURED BY AJM-
 WATER JET MACHINING-(WJM)
 In WJM 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 as used in “Jute Bell Presses”.

 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). Such high velocity water jet can
machine thin sheets/foils of aluminium, leather, textile, frozen food etc.

 In pure WJM, commercially pure water (tap water) is used for machining
purpose. However as the high velocity water jet is discharged from the orifice,
the jet tends to entrain atmospheric air and flares out decreasing its cutting
ability.
PROCESS SETUP-
 EQUIPMENTS OF WJM-
 Reservoir: used to store water to be used in machining operation.

 Pump: pumps water from reservoir.

 Intensifier: is connected to the pump. It pressurizes the water acquired from the
pump to a desired level.

 Accumulator: used to temporarily store pressurized water. It is connected to the

flow regulator through a control valve.

 Control Valve: controls direction and pressure of pressurized water that is to be

supplied to the nozzle.

 Flow regulator: used to regulate flow of water.

 Nozzle: renders the pressurized water as a water jet at high velocity.

 APPLICATIONS-
 Soft and friable materials are easiest to cut.

 Brittle materials are not suitable because they crack or break under the action
of the water jet.

 WJC is the process of choice for cutting sheets of paper, cloth, Kevlar, glass
epoxy, fibre reinforced plastics.

 Also suitable for foods, leather, rubber, insulation, cardboard, automotive

carpeting.

 Titanium and boron can be cut.

 ENVIRONMENTAL ISSUES AND
FUTURE-
 Nowadays, every manufacturing process is being re-evaluated in terms of its impact on the
environment. For example, use of conventional coolants in machining and grinding is
being looked upon critically from the point of view of its impact on environment. The
environmental issues relevant to WJM are,

• water recycling
• spent water disposal
• chip recovery
• abrasive recovery and reuse

 Environmental issues and concerns have lead the researchers to use such mediums and
abrasives that do not require disposal, recycling or lead to pollution. Work is going on in
the area of high-pressure cryogenic jet machining where liquid nitrogen replaces the water
phase and dry ice crystals (solid CO2 crystals) replace the abrasive phase leading to no need
of disposal or waste generation. The removed work material in the form of microchips can
be collected much easily reducing the chances of environmental degradation.
PRODUCT MANUFACTURED BY WJM-
 REFERENCE-
 M. Hashish, A model for abrasive water jet machining, J. Engg. Materials Tech.,
Vol.111, (1989)

 Abhishek Dixit, Vikas Dave, M.R. Baid “WATER JET MACHINING: AN

ADVANCE MANUFACTURING PROCESS” International Journal of Engineering
Research and General Science Volume 3, Issue 2, Part 2, March-April, 2015 ISSN
2091-2730.pp.154-162
THANK YOU..