Non-conventional machining

Introduction and
Abrasive Jet Machining
Identify the characteristics of conventional machining

ii. Identify the characteristics of non traditional machining

iii. Differentiate between conventional and non traditional machining

iv. Classify different non traditional machining processes

v. Identify the need for non traditional machining processes

vi. Describe the basic mechanism of material removal in AJM

vii. Identify major components of AJM equipment

viii. State the working principle of AJM equipment

ix. Draw schematically the AJM equipment

x. Identify the process parameters of AJM

xi. Identify the machining characteristics of AJM

xii. Analyse the effect of process parameters on material removal rate (MRR)

xiii. Draw variation in MRR with different process parameters

xiv. Develop mathematical model relating MRR with abrasive jet machining parameters

xv. List three applications of AJM

xvi. List three limitations of AJM

(i) Introduction
Manufacturing processes can be broadly divided into two groups and they are primary
manufacturing processes and secondary manufacturing processes. The former ones provide
basic shape and size to the material as per designer’s requirement. Casting, forming, powder
metallurgy are such processes to name a few. Secondary manufacturing processes provide the
final shape and size with tighter control on dimension, surface characteristics etc. Material
removal processes are mainly the secondary manufacturing processes.
 Material removal processes once again can be divided into mainly two groups and they
are “Conventional Machining Processes” and “Non-Traditional Manufacturing Processes”.
Examples of conventional machining processes are turning, boring, milling, shaping, broaching,
slotting, grinding etc. Similarly, Abrasive Jet Machining (AJM), Ultrasonic Machining (USM),
Water Jet and Abrasive Water Jet Machining (WJM and AWJM), Electro-discharge Machining
(EDM) are some of the Non Traditional Machining (NTM) Processes.
(ii) Classification of Non Traditional Machining Processes
To classify Non Traditional Machining Processes (NTM), one needs to understand and
analyse the differences and similar characteristics between conventional machining processes
and NTM processes.
Conventional Machining Processes mostly remove material in the form of chips by
applying forces on the work material with a wedge shaped cutting tool that is harder than the
work material under machining condition. Such forces induce plastic deformation within the work
piece leading to shear deformation along the shear plane and chip formation. Fig. 9.1.1 depicts
such chip formation by shear deformation in conventional machining.

Fig.9.1.1 Shear deformation in conventional machining leading to chip formation

Thus the major characteristics of conventional machining are:

• Generally macroscopic chip formation by shear deformation

• Material removal takes place due to application of cutting forces – energy domain can
be classified as mechanical

• Cutting tool is harder than work piece at room temperature as well as under machining
conditions

Non Traditional Machining (NTM) Processes on the other hand are characterised as follows:
 • Material removal may occur with chip formation or even no chip formation may take
place. For example in AJM, chips are of microscopic size and in case of
Electrochemical machining material removal occurs due to electrochemical
dissolution at atomic level

• In NTM, there may not be a physical tool present. For example in laser jet machining,
machining is carried out by laser beam. However in Electrochemical Machining there
is a physical tool that is very much required for machining

• In NTM, the tool need not be harder than the work piece material. For example, in
EDM, copper is used as the tool material to machine hardened steels.

• Mostly NTM processes do not necessarily use mechanical energy to provide material
removal. They use different energy domains to provide machining. For example, in
USM, AJM, WJM mechanical energy is used to machine material, whereas in ECM
electrochemical dissolution constitutes material removal.

Thus classification of NTM processes is carried out depending on the nature of energy used for
material removal. The broad classification is given as follows:

• Mechanical Processes

⎯ Abrasive Jet Machining (AJM)

⎯ Ultrasonic Machining (USM)

⎯ Water Jet Machining (WJM)

⎯ Abrasive Water Jet Machining (AWJM)

• Electrochemical Processes

⎯ Electrochemical Machining (ECM)

⎯ Electro Chemical Grinding (ECG)

⎯ Electro Jet Drilling (EJD)

• Electro-Thermal Processes

⎯ Electro-discharge machining (EDM)

⎯Laser Jet Machining (LJM)

⎯ Electron Beam Machining (EBM)

• Chemical Processes

⎯ Chemical Milling (CHM)

 ⎯ Photochemical Milling (PCM) etc.

Fig. 9.1.2 schematically depicts some of the NTM processes:

(iii) Need for Non Traditional Machining

Conventional machining sufficed the requirement of the industries over the decades. But
new exotic work materials as well as innovative geometric design of products and components
were putting lot of pressure on capabilities of conventional machining processes to manufacture
the components with desired tolerances economically. This led to the development and
establishment of NTM processes in the industry as efficient and economic alternatives to
conventional ones. With development in the NTM processes, currently there are often the first
choice and not an alternative to conventional processes for certain technical requirements. The
following examples are provided where NTM processes are preferred over the conventional
machining process:

Intricate shaped blind hole – e.g. square hole of 15 mmx15 mm with a depth of 30 mm

• Difficult to machine material – e.g. same example as above in Inconel, Ti-alloys or

carbides.
 • Low Stress Grinding – Electrochemical Grinding is preferred as compared to
conventional grinding

• Deep hole with small hole diameter – e.g. φ 1.5 mm hole with l/d = 20

• Machining of composites.
(iv) Abrasive Jet Machining
In Abrasive Jet Machining (AJM), abrasive particles are made to impinge on the work material at
a high velocity. The jet of abrasive particles is carried by carrier gas or air. The high velocity
stream of abrasive is generated by converting the pressure energy of the carrier gas or air to its
kinetic energy and hence high velocity jet. The nozzle directs the abrasive jet in a controlled
manner onto the work material, so that the distance between the nozzle and the work piece and
the impingement angle can be set desirably. The high velocity abrasive particles remove the
material by micro-cutting action as well as brittle fracture of the work material. Fig. 9.1.3
schematically shows the material removal process.

AJM is different from standard shot or sand blasting, as in AJM, finer abrasive grits are used
and the parameters can be controlled more effectively providing better control over product
quality.
In AJM, generally, the abrasive particles of around 50 μm grit size would impinge on the work
material at velocity of 200 m/s from a nozzle of I.D. of 0.5 mm with a stand off distance of
around 2 mm. The kinetic energy of the abrasive particles would be sufficient to provide material
removal due to brittle fracture of the work piece or even micro cutting by the abrasives.
(v) Equipment
In AJM, air is compressed in an air compressor and compressed air at a pressure of around 5
bar is used as the carrier gas as shown in Fig. 9.1.4. Fig. 9.1.4 also shows the other major parts
of the AJM system. Gases like CO2, N2 can also be used as carrier gas which may directly be
issued from a gas cylinder. Generally oxygen is not used as a carrier gas. The carrier gas is

first passed through a pressure regulator to obtain the desired working pressure. The gas is
then passed through an air dryer to remove any residual water vapour. To remove any oil
vapour or particulate contaminant the same is passed through a series of filters. Then the
carrier gas enters a closed chamber known as the mixing chamber. The abrasive particles enter
the chamber from a hopper through a metallic sieve. The sieve is constantly vibrated by an
electromagnetic shaker. The mass flow rate of abrasive (15 gm/min) entering the chamber
depends on the amplitude of vibration of the sieve and its frequency. The abrasive particles are
then carried by the carrier gas to the machining chamber via an electro-magnetic on-off valve.
The machining enclosure is essential to contain the abrasive and machined particles in a safe
and eco-friendly manner. The machining is carried out as high velocity (200 m/s) abrasive
particles are issued from the nozzle onto a work piece traversing under the jet.
(vi) Process Parameters and Machining Characteristics.
The process parameters are listed below:

• Abrasive

⎯ Material – Al2O3 / SiC / glass beads

⎯ Shape – irregular / spherical

⎯ Size – 10 ~ 50 μm

⎯ Mass flow rate – 2 ~ 20 gm/min

• Carrier gas