Introduction to Abrasive
Jet Machining Processes
Mechanical Non-Traditional Machining
USM AJM
Abrasion Abrasives
Abrasives Jet
Slurr Flui
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Work Piece Work Piece
Abrasive Jet Machining (AJM)
Introduction
1. Abrasive Jet Machining is a Non-Traditional Machining process which is
mostly used in machining of hardened metals.
2. In this machining process a focus stream of abrasive particles
are forces to impinge on work piece at high velocity.
3. These high velocity abrasive particles remove metal by brittle fracture or
erosion from work piece.
4. The abrasive particles are typically of 0.025mm diameter and the
air discharges at a pressure of several atmosphere.
5. AJM can be used to cut hard and brittle materials (e.g. germanium, silicon,
mica, glass and ceramics) in a large variety of cutting and deburring.
6. The process is smooth and free from vibration.
7. The variables that affect the cutting phenomena are:
a. Abrasive: composition, strength, shape, size, and mass flow rate.
b. Carrier gas: composition, pressure and velocity.
c. Nozzle: geometry, composition, nozzle-tip distance (Stand off
distance and its orientation).
Principle:
1. This machining process works on the basic
principle of abrasive erosion.
2. If a high velocity (GAS or AIR) along with
abrasive particles strike on a hard or brittle
work piece, it remove some metal at the
striking surface.
3. This metal removal process takes place due to
brittle fracture of metal and also due to micro
cutting by abrasive particle.This is principle
process of abrasive jet machining.
AJM Equipment with Parts
Gas Propulsion System:
The main purpose of gas propulsion system is to provide clean and dry, high velocity
air or gas for machining.
Mostly Air, Carbon Dioxide, Nitrogen etc. are used as gas in gas propulsion system.
This system consists, compressor, air filter and drier.
The gas used in this system should easily available.
First gas is compressed into a compressor, then the compressed gas is sends to filler
and drier where all dust and unwanted particle along with moisture is remove from
it. Clean air is then send to mixing chamber.
Abrasive Feeder:
Abrasive feeder is used to provide abrasive particles in mixing chamber.
It is fed through a sieve which vibrates at 50-60Hz and mixing ratio is control by the
vibration of the sieve and its amplitude.
Abrasive:
These are the main particles which take part in machining process.
These particles should have high metal removal rate and accuracy.
The most common abrasive particles used are Aluminium Oxide, Silicon
Carbide, Boron Carbide, etc.
The selection of abrasive particle is depends upon material of work piece, speed of
machining, and machining environment.
Cutting Nozzle:
To direct the abrasive particle on work piece cutting nozzles are used.
They are usually made by Tungsten Carbide.
They are available in both circular and square cross section.
Its life is usually low about 30 hours for Tungsten Carbide.
Machining Chamber:
It is fully closed air tight chamber which control the concentration of
abrasive particle around work piece.
This is equipped with a vacuum dust collector which collect used abrasive particle
and removed material from mixing chamber.
Working Process:
The basic concept of abrasive jet machining is
abrasive erosion or metal cutting by high
velocity abrasive particle. Its working process
can be easily summarized into following point.
First gas or air is compressed into gas
compressor. There the density and pressure of
gas increases.
Now this compressed gas send to filtration unit, where dust and other suspended
particle removed from it.
This clean gas sends to drier, which absorb moisture from it. It is used to avoid
water or oil contamination of abrasive power.
Working Process: Cont..
This clean and dry gas is send to mixing chamber where abrasive feeder
feed
abrasive particle in it. The abrasive particle is about 50 micro meter grit size.
This high pressuring abrasive carried gas send to nozzle where its pressure energy
converted into kinetic energy. The velocity of abrasive particle leaving the nozzle is
about 200m/s.
The standoff distance between work piece and nozzle is about 2mm.
These high velocity abrasive particles impinge on work piece. These high velocity
abrasive particles remove the material by micro cutting action as well as brittle
fracture of the work material.
AJM Process Parameters:
For successful utilization of AJM process, it is necessary to
analyse
the following process criteria
Material Removal Rate (MRR)
Geometry of the Work-Piece
Surface Finish of the Work-Piece
Wear Rate of the Nozzle
Process Parameters influencing AJM processes are as the following:
Size m
Material Shape
Abrasives (µm) (g/min)
Al2O3, SiC, etc Irregular 10 − 50 2 − 20
Ρ V P
Composition
Carrier Gas (kg/m3) (m/s) (bars)
Air,CO2,N2 1.3 500 − 700 2 − 10
SOD V
Impinge Mixing ratio
Abrasive Jet (mm) (m/s)
0.5 - 15 60 − 90◦ 100 − 300 V˙ abr /
Diameter Life V˙ NTD
gas
Material
Nozzle (mm) (hrs) (mm)
WC, Sapphire 0.2 - 0.8 12 - 300 0.25 - 75
- SOD-Stand of Distance, NTD-Nozzle to Tip
Distance
Process Parameters:
The process characteristics can be evaluated by judging:
1. The MRR
2. The Geometry of the Cut
3. The Roughness of the Surface Produced and
4. The Rate of Nozzle Wear
The major parameters which control these quantities are:
1. The abrasive (composition, strength, size and
mass flow rate)
2. The gas (composition, pressure and velocity)
3. The nozzle (geometry, material, distance
from and inclination to the work surface)
The Abrasives:
Mainly two types of abrasives are used
(1) Aluminum Oxide (2) Sodium Bicarbonate (3) Dolomite
(4) Silicon Carbide (5) Glass beads
Grains with a diameter 10-50 microns are readily available.
For good wear action on the surfaces, the abrasive grains should have
sharp edges.
The mass flow rate of the abrasive particles depends on the pressure and
the flow rate of the gas.
Reuse of the abrasive powder is normally not recommended because of a
decrease of cutting capacity and clogging of the nozzle orifices due to
contamination.
