Abrasive Jet Machining
(AJM)
Dr. Sanjeev Sharma
Prof., Deptt. of Mech. Engg.
CEC, Landran
Introduction
Water Jet Machining (WJM) and Abrasive Water Jet Machining
(AWJM) are two non-traditional or non-conventional machining
processes.
They belong to mechanical group of non-conventional processes like
Ultrasonic Machining (USM) and Abrasive Jet Machining (AJM).
In these processes (WJM and AJWM), the mechanical energy of water
and abrasive phases are used to achieve material removal or
machining.
Introduction
A jet of inert gas consisting of very fine abrasive particles
strikes the work piece at high velocity (usually between
200-400 m/s) resulting in material removal through
chipping/ erosive action.
This erosive action has been employed for cutting,
cleaning, etching, polishing and de-burring.
Introduction
This method of material removal is quite effective on hard
and / or brittle materials (viz glass,- silicon, tungsten,
ceramics, etc)
Not so effective on soft materials like aluminum, rubber,
etc.
It can produce fine and complicated details on the parts
made of very brittle materials [Benedict, 1987].
Elements
Gas Propulsion System
Abrasive Feeder
Machining Chamber
AJM Nozzle
Abrasive jet machining Setup
Schematic diagram of abrasive jet machining (AJM)
Abrasive jet machining
Gas Propulsion System
Supplies clean and dry gas (air, nitrogen, or CO 2) to propel the
abrasive particles.
The gas may be supplied either by a compressor or a cylinder.
In case of a compressor, air filter-cum-drier should be used to avoid
water or oil contamination of the abrasive powder.
The gas should be nontoxic, cheap, and easily available.
It should not excessively spread when discharged.
Abrasive Feeder
Abrasive quantity is controlled by inducing vibration to the
feeder.
The particles are propelled by carrier gas to a mixing
chamber.
The air abrasive mixture moves further to the nozzle.
The nozzle imparts high velocity to the mixture which is
directed at the work piece surface.
Machining Chamber
The machining chamber is well closed so that the
concentration of the abrasive particles around the working
chamber does not reach to the harmful limit.
Machining chamber is equipped with a vacuum dust
collector.
Special consideration should be given to the dust collection
system if the toxic materials (say,beryllium) are being
machined.
AJM Nozzle
Nozzle is usually made of tungsten carbide or sapphire
(usual life =300 hr) which has high resistance to wear.
Nozzle pressure is generally maintained between 2-8.5
kgf/cm2→ W/P material, MRR
Nozzle is made of either circular or rectangular cross-
section.
Contd…
Increase in the wear of a nozzle, the divergence of the jet
stream increases resulting in more stray cutting and high
inaccuracy.
The stray cutting can be controlled by the use of masks made of
soft materials like rubber (for less accurate work, or poor
edge definition), or metals (for more accurate works or sharp
edge definition).
Mask covers only that part of the job where machining is not
desirable.
Abrasives
Aluminum oxide (Al203), silicon carbide (SiC), glass
beads, crushed glass, and sodium bicarbonate.
Selection of abrasives depends upon the type of
work material, material removal rate (MRR), and
machining accuracy desired.
Contd…
Al203 is good for cleaning, cutting, and
deburring
SiC is also used for the similar
applications but for harder work
materials.
For obtaining matte finish, glass beads
are good while crushed glass performs
better for giving sharper edges.
Contd…
Cleaning, deburring, and cutting of soft
materials are better performed by sodium
bicarbonate.
sizes of abrasive particles available in the
market range from 10 to 50µm.
Small abrasive particles are used for cleaning
and polishing while large particles perform
better during cutting.
Contd…
Re-use of the abrasives is not recommended
Abrasives get contaminated with metallic
chips which may block the nozzle passage.
Cutting ability of the used abrasive particles
goes down.
Further, cost of the abrasives is also low.
Parametric Analysis
Stand-off-distance (ie. SOD, or
sometimes called as nozzle tip distance
- NTD)
Type and size of abrasive particles
Flow rate of abrasive
Gas pressure
Work material and feed rate
Stand -Off-Distance
In a range of SOD which usually varies
from 0.75 to 1.0 mm, the MRR is
maximum.
A decrease in SOD improves accuracy,
decreases kerf width, and reduces taper
in the machined groove.
Relationship between SOD and
shaped of machined cavity
Abrasive Flow Rate
As abrasive flow rate increases, the number
of abrasive-particles cutting the work piece
also increases thereby increasing MRR.
However, with a further increase in abrasive
flow rate (other parameters remaining
unchanged), the abrasive flow velocity goes
down. This decrease in abrasive flow velocity
causes a reduction in MRRg
Contd…
Nozzle Pressure
Kinetic energy (K. E.) of the abrasive particles is
responsible for removal of material by erosion
process.
Abrasives must impinge on the work surface
with a certain minimum velocity so that the
erosion can take place.
This minimum velocity for machining glass by
SiC particles (size: 25 µm) is found to be
around 150 m/s.
Contd…
Mixing Ratio
Contd…
Mixing ratio (M) also influences MRRV
An increase in the value of 'M' increases
MRRv but a large value of 'M' may
decrease jet velocity and sometimes may
block the nozzle.
Thus, an optimum value of mixing ratio
has been observed that gives maximum
MRRv.
Effect of SOD on MRR for
various mixing ratio
Process Capabilities
Although AJM gives low MRRv (approx.
0.015 cm3/min) but it can easily
produce intricate details in hard and
brittle materials.
Production of narrow slots (0.12 - 0.25
mm), low tolerance (± 0.12 mm), good
surface finish (0.25 - 1.25µm), and
sharp radius (0.2 mm)
Contd…
Steels up to 1.5 mm thick and glass up to 6.3
mm thick have been possible to cut by AJM
but at very low MRR and large taper.
The process has a special application for
machining thin-sectioned brittle materials,
particularly in the areas which are inaccessible
for conventional machining methods.
Heat generation is very low the resulting
surface damage is also insignificant.
Applications
Manufacture of electronic devices
Deburring of plastics, making of nylon
and teflon parts, marking on electronic
products, permanent marking on rubber
stencils, deflashing small castings,
cutting titanium foil, and drilling glass
wafers.
Applications
It is also used for engraving registration
numbers, and on the toughened glass
used for car windows.
This process is also used for frosting
glass surfaces and cutting thin-
sectioned fragile components.
