Abrasive Jet Machining

Process - Contd
Mechanical Non-Traditional Machining

USM AJM

Abrasion Abrasives

Abrasives Jet

Slurr Flui
y d
Work Piece Work Piece
AJM Equipment with
Parts
 There is an optimum mixing ratio (mass fraction of the
abrasive in the jet) for which the metal removal rate is the
highest.
 When the mass flow rate of the abrasive increases the
material removal rate also increases.
m rr

m rr

mixing ratio abrasive flow rate

 The Nozzle:
 The nozzle is one of the most vital elements controlling the
process characteristics.
 The nozzle material should be hard to avoid any significant wear due
to the flowing abrasive. [Normally WC (avg. life: 12-30 hrs.) or Sapphire
(Appr. = 300 hrs.) are used]
 For a normal operation the cross-sectional area of the orifice can be
either circular or rectangular and between 0.05- 0.2mm2 .

Right angled head Straight head

 Nozzle to Tip Distance (Stand off
distance)

1. The nozzle tipdistance (NTD) or the stand off

distance is a critical parameter in AJM.
 Nozzle to Tip Distance (Stand off
distance)
2. The NTD not only affects the MRR from the work surface but also
the shape and size of the cavity produced.

3. As shown in the figure below, when the NTD increases, the

velocity of the abrasive particles impinging on the work surface
increases due to their acceleration after they leave the nozzle.
This increases the MRR.

4. With a further increase in the NTD, the velocity reduces due to

the drag of the atmosphere which initially checks the increase in
MRR and then decreases it.
 Photographs of the Actual Machined Cavity Profile
at Different NTD
Profile of the machined cavity at different stand off distances

2mm 6mm 10mm

14mm 16mm 20mm

The Gas

 Mostly Air,Carbon Dioxide, Nitrogen etc. are used as

gas in gas propulsion system.
 TheAJM unit normally operates at a pressure of
0.2-1.0 N/mm2 .
 Thecomposition of gas at high velocity has a
significant impact on the MRR even if the mixing ratio is not
changed.
Effect of Abrasive Flow Rate on
MRR

(g/min)
MRR

Abrasive flow rate

(g/min)
1. As the flow rate increases upto maxima, More number of
abrasive particles hit the surface. This increases the MRR.

2. If flow rate is greater than the optimum, velocity of the

jet decreases hence MRR also decreases.
Effect of Nozzle Pressure on
MRR

Mixing Ratio

mm3/s
MRR,

Critical Pressure

Nozzle Pressure, MPa

1. Little effect on MRR.

2. Kinetic Energy removes material, due to erosive action.
3. Certain minimum velocity for the given material of
workpiece.
Effect of Mixing Ratio on
MRR

mixing
ratio

mm3/s
MRR
mass
ratio
Mixing
Ratio
Note:
1) Mixing Ratio(m) is the ratio of volume flow rate of abrasive to the
volume flow rate of carrier gas.
2) Mass Ratio (α) is the ratio of mass flow rate of abrasive to the
mass flow rate of abrasive and gas carrier
Process Capabilities of AJM
1. Low MRR.

2. Intricate Details Can be Produced.

3. Narrow Slots (0.12 to 0.25 mm) can be made.

4. Low Tolerances (−0.12 to +0.12mm) can be obtained.

5. Minimization of Taper Angle of Nozzle w.r.t Work Piece.

6. Thin Sectioned, Brittle Material, Inaccessible Areas can be

easily Machined.

7. Almost No Surface Damage.

Advantages:
1. High surface finish.
2. It can machine heat sensitive material.
3. It is free from vibration
4. Initialization cost is low compare to other non-traditional processes.
5. Thin section can be machined easily.

Disadvantages:
1. Low metal removal rate.
2. Abrasive particle can embedded into work piece mostly in soft metals.
3. Nozzle life is limited so it needs frequently replacement.
4. Abrasive particle cannot be reuse in this process.
5. It cannot use for machine soft and ductile material.
Applications of AJM

1. This is used for abrading and frosting glass more economically as

compared to etching or grinding.
2. Cleaning of metallic smears on ceramics, oxides on metals,
resistive coatings.
3. Manufacture of electronic devices including fragile components
germanium, silicon, etc
4. Deburring of plastics, nylon, teflon parts, etc
5. Deflashing of small casting
6. Drilling glass wafers, etc.

7. Cutting, marking, engraving on cutting thin sectioned

Applications of AJM
8. Glass frosting

9. Paint removal

10. Textile and leather industry

11. Register trimming can be done very easily and micro module fabrication

for electrical contact, semiconductor processing can also be done

effectively.

12. It is a good method for deburring small hole like in hypodermic needles

and for small milled slots in hard metallic components.