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Abrasive Jet Machining
Introduction
A stream of abrasive grains (Al2O3 or SiC) is carried by high
pressure gas or air (compressed).
Impinges on the work surface at very high velocity through a
nozzle of 0.3 to 0.5 mm diameter.
Sand Blasting (SB) - a similar process
The major differences between are SB and AJM
(i) smaller diameter abrasives
(ii) a more finely controlled delivery system
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Introduction
Material removal – by mechanical abrasion action of the high
velocity abrasive particles.
Best suited for hole drilling in super hard materials.
Typically used to cut, clean, peen, deburr, deflash and etch
glass, ceramics and other hard materials.
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Machining System
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Machining System – Contd.
A gas (Nitrogen, CO2 or air) is supplied at 2 – 8 kg/cm2
Oxygen should never be used. (because, it causes violent
chemical action with the work piece chips or abrasive
particles).
Gas passes through a mixing chamber after filtration and
regulation.
In the mixing chamber, abrasive particles (10 – 40 m) are
present and vibrated at 50 Hz.
Amplitude of vibration – to control the feed rate of abrasives.
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Machining System – Contd.
(Gas + abrasives) - passed through a 0.45 mm diameter
tungsten carbide nozzle at a speed of 150 – 300 m/s.
The nozzle is directed over the area to be machined.
Aluminium oxide (Al2O3) and silicon carbide (SiC) powders are
used for heavy cleaning, cutting and deburring.
Magnesium carbonate is recommended for use in light
cleaning and etching.
Sodium bicarbonate – fine cleaning and cutting of soft
materials.
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Machining System – Contd.
Commercial grade powders are not suitable – b’cos their sizes
are not well classified. Also, they may contain silica which can
cause a health hazard.
Abrasive powders are not reused. B’cos, contaminations and
worn grits will reduce the machining rate (MRR).
The nozzle stand off distance is 0.81 mm.
Relative motion between nozzle and workpiece – can be
manual
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Machining System – Contd.
Or automatically controlled using cam drives, tracer mechanisms
or using computer controlled according to the cut geometry
required.
Masks of copper, glass or rubber – can be used to concentrate
the jet stream of abrasives to a confined area on the work piece.
Intricate and precise shapes can be produced using masks with
corresponding contours.
Dust removal or collecting equipment must be incorporated to
protect the environment.
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Material Removal
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Material Removal
The abrasive particles from the nozzle follow parallel paths for a
short distance
Then the abrasive jet flares outward like a narrow cone.
When the sharp-edged abrasive particles of Al2O3 or SiC hit a
brittle and fragile material at high speed, tiny brittle fractures are
created from which small particles dislodge.
The dislodged particles are carried away by the air or gas.
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Process Parameters
MRR, machining accuracy, surface roughness and nozzle wear
are influenced by
Size and distance of the nozzle.
Composition, strength, size, and shape of abrasives
Flow rate
Composition, pressure, and velocity of the carrier gas.
MRR is mainly dependent on the flow rate and size of abrasives.
Larger grain sizes produce greater removal rates.
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Process Characteristics
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Applications
Drilling holes, cutting slots, cleaning hard surfaces, deburring, polishing and radiusing.
Deburring of cross holes, slots, and threads in small precision parts that require a burr-
free finish, such as hydraulic valves, aircraft fuel systems, and medical appliances.
Machining intricate shapes or holes in sensitive, brittle, thin, or difficult-to-machine
materials.
Insulation stripping and wire cleaning without affecting the conductor.
Micro-deburring of hypodermic needles.
Frosting glass and trimming of circuit boards, hybrid circuit resistors, capacitors, silicon,
and gallium.
Removal of films and delicate cleaning of irregular surfaces because the abrasive stream
is able to follow contours.
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Advantages
Because AJM is a cool machining process, it is best suited for machining brittle and
heat-sensitive materials like glass, quartz, sapphire, and ceramics.
The process is used for machining super alloys and refractory materials.
It is not reactive with any work piece material.
No tool changes are required.
Intricate parts of sharp corners can be machined.
The machined materials do not experience hardening.
No initial hole is required for starting the operation as required by wire EDM.
Material utilization is high.
It can machine thin materials.
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Limitations
The removal rate is slow.
Stray cutting can’t be avoided (low accuracy of 0.1 mm).
The tapering effect may occur especially when drilling in metals.
The abrasive may get impeded in the work surface.
Suitable dust-collecting systems should be provided.
Soft materials can’t be machined by the process.
Silica dust may be a health hazard.
Ordinary shop air should be filtered to remove moisture and oil.
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