A Report

on

Abrasive Jet Machining

by

Sagar Mani Dahal 2009-UME-520

Department of Mechanical Engineering MNIT Jaipur

Introduction
Abrasive Jet Machining (AJM) is the removal of material from a work piece by the application of a high speed stream of abrasive particles carried in gas medium from a nozzle. The AJM process differs from conventional sand blasting in that the abrasive is much finer and the process parameters and cutting action are carefully controlled. The process is used chiefly to cut intricate shapes in hard and brittle materials which are sensitive to heat and have a tendency to chip easily. The process is also used for debarring and cleaning operations. AJM is inherently free from chatter and vibration problems. The cutting action is cool because the carrier gas serves as a coolant.

Equipment
A schematic layout of AJM is shown in Fig1. The filtered gas, supplied under pressure to the mixing chamber containing the abrasive powder and vibrating at 50 c/s, entrains the abrasive particle and is the passed into a connecting hose. This abrasive and gas mixture emerges from a small nozzle at high velocity. The abrasive powder feed rate is controlled by the amplitude of vibration of the mixing chamber. A pressure regulator controls the gas flow and pressure.

The nozzle is mounted on a fixture. Either the work piece or the nozzle is moved by cams pantograph or other suitable mechanisms to control the size and shape of the cut. Hand operation is sometimes adequate to remove surface contaminations or in cutting where accuracy is not very critical. Dust removal equipment is necessary to protect the environment. Commercial bench mounted units including all controls, motion producing devices, and dust control equipment are available.

FIG1: SCHEMATIC LAYOUT OF ABRASIVE JET MACHINE The major components 1. 2. 3. 4. 5. 6. 7. 8. Air compressor. Air filter. Dehumidifier. Pressure Gauge. Pressure Regulator. Vibrator or Mixer. Nozzle. Arrangement to hold the work piece.

Process
In Abrasive jet machining abrasive particles are made to impinge on work material at high velocity. Jet of abrasive particles is carried by carrier gas or air. The high velocity stream of abrasives is generated by converting pressure energy of carrier gas or air to its Kinetic energy and hence high velocity jet. Nozzles direct abrasive jet in a controlled manner onto work material. The high velocity abrasive particles remove the material by micro-cutting action as well as brittle fracture of the work material.

This is a process of removal of material by impact erosion through the action of concentrated high velocity stream of grit abrasives entrained in high velocity gas stream. AJM is different from shot or sand blasting, as in AJM, finer abrasive grits are used and parameters can be controlled more effectively providing better control over product quality. In AJM, generally, the abrasive particles of around 50 microns grit size would impinge on the work material at velocity of 200 m/s from a nozzle of ID 0.5mm with a standoff distance of around 2mm. The kinetic energy of the abrasive particles would sufficient to provide material removal due to brittle fracture of the work piece or even micro cutting by the abrasives. Physics of the Process: Fine particles (0.025mm) are accelerated in a gas stream The particle are directed towards the focus of machining As the particles impact the surface, it causes a micro fracture, and gas carries fractured particles away Brittle and fragile work better

Process parameters
For successful utilization of AJM process, it is necessary to analyze the following process criteria. 1. Material removal rate 2. Geometry and surface finish of work piece 3. Wear rate of the nozzle However, Process criteria are generally influenced by the process parameters as enumerated below: Abrasives a) material Al2O3 SiC Glass beads Crushed glass Sodium bi carbonate b) shape irregular/regular c) Size 10 to 50 microns d) Mass flow 2-20 gm/min a) b) c) d) e) Carrier Gas Composition Air, CO2, N2 Density 1 . 3 kg/m3 Velocity - 5 0 0 to 700 m/s Pressure - 2 to 10 bar Flow rate - 5 to 30 microns

Abrasive Jet b) Velocity - 100 to 300 m/s c) Mixing ratio Volume flow rate of abrasives/Volume flow rate of gas d) Standoff distance SOD- 0.5 to 15mm. e) Impingement angle 60 to 90 deg. Nozzle a) Material WC/Sapphire b) Diameter 0.2 to 0.8 mm c) Life 300 hours for sapphire, 20 to 30 hours for WC

V a r i a b l e s in Abrasive Jet Machine:

The variables that influence the rate of metal removal and accuracy of machining in this process is: 1. 2. 3. Carrier gas Types of abrasive Size of abrasive grain

4. 5. 6. 7. 8. 9.

Velocity of abrasive jet Flow rate of abrasive Work material Geometry, composition and material of nozzle Nozzle work distance (standoff distance) Shape of cut and operation type

C h a r a c t e r i s t i c s of different Variables:

Medium Abrasive Flow rate of abrasive Velocity Pressure Nozzle size Material of nozzle Nozzle life Standoff distance Work material

Air , CO2 ,N2 SiC, Al2O3 (of size 20 to 50 ) 3 to 20 gram/min 150 to 300 m/min 2 to 8 kg/cm2 0.07 to 0.40 mm WC, Sapphire 12 to 300 hr 0.25 to 15 mm (8mm generally) Non Metals like glass, ceramics, and granites. Metals and alloys of hard materials like germanium, silicon etc

part application

Drilling, cutting, deburring, cleaning

Advantages:
High surface finish can be obtained depending upon the grain sizes Particle size ( in microns) Surface roughness ( in microns) 10 25 to 27 50 0.152 to 0.203 0.355 to 0.675 0.965 to 1.27 Depth of damage is low ( around2.5 microns) It provides cool cutting action, so it can machine delicate and heat sensitive material Process is free from chatter and vibration as there is no contact between the tool and work piece Capital cost is low and it is easy to operate and maintain AJM. Thin sections of hard brittle materials like germanium, mica, silicon, glass and ceramics can be machined. It has the capability of cutting holes of intricate shape in hard materials.

Disadvantages:
Limited capacity due to low MRR. (for glass 40 g/min) Abrasives may get embedded in the work surface, especially while machining soft material like elastomers or soft plastics. A dust collection system is a basic requirement to prevent atmospheric pollution and health hazards. Abrasive powders cannot be reused as the sharp edges are worn and smaller particles can clog the nozzle. Short standoff distances when used for cutting, damages the n ozzle. Stray cutting is difficult to avoid. The accuracy of cutting is hampered by tapering of hole due to unavoidable flaring of abrasive jet. Nozzle life is limited. (Around 300 hours.)

Application:
This is used for abrading and frosting glass more economically as compared to etching or grinding Cleaning of metallic smears on ceramics, oxides on metals, resistive coating etc. AJM is useful in manufacture of electronic devices , drilling of glass wafers, de burring of plastics, making of nylon and Teflon parts permanent marking on rubber stencils, cutting titanium foils Deflashing small castings, engraving registration numbers on toughened glass used for car windows Used for cutting thin fragile components like germanium, silicon etc. Register trimming can be done very easily and micro module fabrication for electrical contact, semiconductor processing can also be done effectively. Used for drilling, cutting, deburring etching and polishing of hard and brittle materials. Most suitable for machining brittle and heat sensitive materials like glass, quartz, sapphire, mica, ceramics germanium, silicon and gallium. It is also good method for deburring small hole like in hypodermic needles and for small milled slots in hard metallic components.