Seminar

ON

ICE JET MACHINING

GUIDED BY
PROF. N. D. GHETIYA

Prepared by
Virendra
11BME050
 OUTLINE

Introduction

Generation of the Ice and apparatus

Hardness Of Ice particle

Comparison of AWJ, WJ & IJM

 Introduction

 Machining is a broad term to describe removal

of material from a workpiece.

Machining

Traditional machining processes Non-Traditional machining processes

Presence Relative
of tool motion Traditiona
harder between l
then Tool and machining
workpiece work

• Otherwise the process is non traditional

•IJM is a non-traditional machining
process
 Why Non-traitional machining process

• If
Traditional machining processes are UNSATISFACTORY OR UNECONOMICAL

Work piece MATERIAL is too HARD, STRONG, OR TOUGH

Work piece is TOO FLEXIBLE TO RESIST CUTTING FORCES or TOO DIFFICULT TO

CLAMP.

TEMPERATURE RISE or residual stresses are undesirable or

UNACCEPTABLE.

Part SHAPE is very COMPLEX with internal or external profiles or small holes.
 What is ice jet machining?

• In Abrasive water Jet Machining process(AWJM)

abrasive particles like silicon carbide and aluminum
oxide are used for machining.
• Ice jet machining is Derivative of AWJM machining
process in which ice particles are used in place of
abrasive particles.
• The ice particles can be prepared beforehand using an
ice particle generator, stored in a reservoir and then fed
to the conventional entrainment based jetting head.
 AWJ and IJ
• In AWJ, waste of water is very high as waterjet
contains abrasive particles. To reuse the water
very complicated water cleaning system has to
be employed.
• While in IJ, ice is used instead of Abrasives. So
as ice melts into the water, water treatment
gets eliminated and we can reuse the water.
• Also solid waste is produced in the AWJ
technology and it pollutes the environment.
• While compared to AWJ, IJ technology is
environmental friendly.
Use of the technology
 Other Processes done with use of ice
Dry ICE DEBURRING PROCESS
 Removal of burrs from edges and holes.
 Where burrs could not be removed with any other
means like filing or grinding.
Deburrig
Dry ICE BLASTING PROCESSES
 Used for cleaning purpose
 Cleaning of engine block can be done with ice blasting
process effectively
Blasting process
Generation of ice
Generation of ice
There are 2 approaches:

Generating the ice in a generator

1
●

before mixing it to the water jet.

2 Forming ice particles during water jet formation

●
●

by introducing a cooling gas like liquid nitrogen.

Using Ice Generator
 Figure shows ice generation
by introducing the liquid
nitrogen to the atomized
water droplets.
 Temperature of the liquid
nitrogen is -196°C.
 As the water comes into
contact with liquid nitrogen it
is converted into ice
particles.
 It is collected into the storage
tank and additionally cooled.
By introducing cryogenic gas to water jet

• Liquid Nitrogen is
directly introduced to
the jet of the ice.
• Due to low temperature
of the LN, ice particles
are formed into the jet
of ice.
 Apparatus
• Apparatus for the IJM are different depending
upon the procedure by which the ice particles
are generated.
• But,
basically components like nozzle, compressor,
atomizer etc remains same.
Apparatus using ice particle generator
• The compressor used for the purpose can
produce maximum pressure of 340 Mpa.
• The ultrasonic atomizer used in the ice particle
generator can produce uniform water droplets
of 45 to 90 microns and 2 ltr/hr to 12 ltr/hr.
• The diameter of the nozzle is 0.175mm and
diameter of focusing tube is 0.75mm.
• Standoff distance is kept 3mm to 5mm.
Ice formed at 8° C and 60 micrometer. Mean dia.
Of the ice was found to be 91.8microns
IceJet machning apparatus developed under Project ICEJET
TECNALIA, UL, IAMCUT
 Basic characteristics
• WATER PRESSURE:50 to 700 Mpa
for harder materials: 700 Mpa
for softer materials: 50 Mpa
• Water nozzel diameter:0.1mm to 0.3mm
• Speed of water jet:500 to 900 m/s
• No heat affected zones.
• Treatment of all kind of materials.
Hardness of Ice Crystal

• All the ice found on earth, Crystal Structure of

Ice is Hexagonal Closed Pack (HCP)
• For study of the hardness of ice, we have to
know about the Crystal axis(c-axis) ice crystal.
• The hardness of the ice is not isotropic. After
experiments it is found that hardness changes
with the orientation of c-axis.
Crystal axis of the Ice
 Brinell Hardness Test
• An Olsen Baby Brinell Hardness Tester was
used.
• The machine comes equipped with a 1/16 inch
ball to be used with a load of 12.61 kg.
• Preliminary tests with ice samples showed
that this load caused excessive cracking
SO,
Modifications had to be done.
 Modifications in the equipment
1. The 12.61 kg. Load was replaced by a
platform on which different weights could be
placed, and
2. The 1/16 inch ball was replaced by a
hardened 1/8-inch ball. The weight of the
ball stem plus platform was 570 g. which
was added to the weights placed on the
platform to give the total load applied.
 Specimen of Ice
• Approximately 7×4×1 cm cubes were used,
oriented so that the c-axis Lay parallel to
the large face of one plate and normal to
the large face of the other.
• Polished to a mirror finish, and freeze onto
glass sheet to provide hard base.
 Calculation of BHN
• Brinell hardness numbers were computed from the
standard Brinell formula:

• Where,
• H is the Brinell hardness number
• K is the applied load in kilograms
• D is the diameter of steel ball in mm.
• d is the diameter of the impression in mm.
 Modified equation
• As standard equipment was not used, the
equation also had to be modified.

Where
k is the hardness number
ǝ is the width of the cut in microns
 Measuring the results
• The specimen was coated with liquid
polystyrene.
• Because the indentations were made at low
temperature, and measurements were made at
higher temp. so considerable fogging was
there.
• So for accurate results, indentation made on
the ice was measured on the polystyrene sheet.
Results
• By the experiment a
graph was plotted of
BHN vs Temprature and
it was found that the
hardness of ice
increases with decrease
in temperature.
• After doing the experiment it was found that
the hardness of the ice particle was higher
parallel to the c axis and less perpendicular to
the c axis of the ice particle.
• BHN of ice was found to be ranging between 4
to 17.
Comparison of AWJ, WJ and IJM

Comparative study of material Drilling by WJ and IJ

Cost analysis for AWJ, WJ and IJM

Cost in Rupees/hour
 Conclusion
• By doing the technical analysis of the IceJet
technology it can be concluded that
production and injection of ice particles in to
the water jet it is not a complicated task but it
requires continuous monitoring of the process
to control the temperatures in order to avoid
clogging and melting of the ice particles.
However this can be automated.
 Conclusion
• By doing the economic analysis, it can be seen
that costs are very similar for AWJ and IJ.
• Most significant expense is the cost of abrasive
particles.
• The costs of AWJ will reach the costs of IceJet in
the near future as abrasives are minerals & are
limited in source.
• Ice Jet is an environmentally friendly process
which makes worth its value.
Questions?
Thank You