Abrasive Jet Machining

(AJM)
BY
NISHTHA CHOUKSEY
0201IP121045

INTRODUCTION
Abrasive jet machining is the material removal process where the material is removed
by high velocity stream of air/gas or water and abrasive mixture .
An abrasive is small, hard particle having sharp edges and an irregular shape .
High velocity jet is aimed at a surface under controller condition .

Introduction(cotd.)

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

smaller diameter abrasives

a more finely controlled delivery system

Material removal by mechanical abrasion action of the high velocity abrasive

particles.

Best suited for hole drilling in superhard materials.

Typically used to cut, clean, peen, deburr, deflash and etch glass, ceramics
and other hard materials.

Machining System

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 workpiece 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.
(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.

Machining System Contd.

Aluminium oxide (Al2O3) and silicon carbide (SiC) powders are

used for heavy cleaning, cutting and debarring.

Magnesium carbonate is recommended for use in light cleaning

and etching.

Sodium bicorbonate fine cleaning and cutting of soft materials.

Commercial grade powders are not suitable because their sizes

are not well classified. Also, they may contain silica which can
cause a health hazard.

Abrasive powders are not reused. because, contaminations and

worn grits will reduce the machining rate (MRR).

The nozzle stand off distance is 0.81 mm.

6

Machining System Contd.

Relative motion between nozzle and workpiece can be manual

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 workpiece.

Intricate and precise shapes can be produced using masks with

corresponding contours.

Dust removal or collecting equipment must be incorporated to

protect the environment.

Components of Abrasive Jet

Machining
o Abrasive delivery system
o Control system
o Pump
o Nozzle
o Mixing tube
o Motion system

1. Abrasive Delivery System

Auto abrasive delivery system has the capability of storing abrasive
& delivery the abrasive to the bucket . Its works auto programming
system by help of once measuring record & no adjustment or fine
tuning system . High sensitive sensor gives extremely reliable &
repeatable .

2. Control system
The control algorithm that computes exactly how the feed rate
should vary for a given geometry in a given material to make a
precise part .

The algorithm actually determines desired variation in the feed

rate & the tool path to provide an extremely smooth feed rate .

3. PUMP
Crankshaft & intensifier pump are mainly use in the abrasive jet
machine .
The intensifier pump was the only
pump capable of reliably creating
pressures high .
Crankshaft pumps are more efficient than intensifier pumps
because they do not require a power robbing hydraulic system
ultra high pressure & more stroke per minute .

4.Nozzle
All abrasive jet systems use the same basic two stage nozzle .
First , water passes through a small diameter jewel orifice to form
a narrow jet .
The abrasive particles are accelerated by the moving
stream of water & they pass into a long hollow
cylindrical ceramic mixing tube.
Generally two type of nozzle
head .

use , right angle head & straight

NOZZLE

5. Mixing tube
The mixing tube is where the abrasive mixes with the high
pressure water .

The mixing tube should be

replaced when tolerances drop
below acceptable levels .For
maximum accuracy , replace the
mixing tube
more frequently .

6.Motion system
In order to make precision parts , an abrasive
jet system must have a precision x-y table and
motion control system .
Tables fall into three general categories .
Floor-mounted gantry systems
Integrated table/gantry systems
Floor-mounted cantilever systems

Working

Process

High pressure water starts at the pump , and is delivered through

special high pressure plumbing to the nozzle .
At the nozzle , abrasive is introduced & as the abrasive/water
mixture exits , cutting is performed .
Once the jet has exited the nozzle , the energy is dissipated into
the catch tank , which is usually full of water & debris from
previous cut .

Water Jet and AbArasive Water Jet

Machining

WJM - Pure
WJM - with stabilizer
AWJM entrained three phase
abrasive, water and air
AWJM suspended two phase
abrasive and water
o Direct pumping
o Indirect pumping
o Bypass pumping

Water Jet and Abrasive Water Jet

Machining

Components of AWJM
Catcher

(a) water basin

(b) steel/WC/ceramic balls

(c) catcher plates (TiB2)

Components of AWJM

Components of AWJM

Fig . Schematic diagram of AJM

Abrasive Jet Machining

AJM features
There are main features of AJM
Obtainable tolerances
Material to machine
Material thickness
Accuracy of table
Stability of table
Control abrasive jet

Machine

Around curves

aspects

Inside corner
Feed rate
Acceleration
Nozzle focus
Speed cutting
Pump pressure
Hardness & thickness
Software controlling the motion
Power at the nozzle

Types of abrasive
materials
Different types of abrasive are used in abrasive jet machining like
garnet , aluminium oxide , olivine , silica sand , silicon carbide ,etc.
Virtually any material can be cut by using abrasive jet machining
method , i.e harder materials like titanium to steel.
Abrasive particles must be hard ,high toughness,
irregular in shape & edges should be sharp .

Modelling

Photographic view of kerf (cross section)

General Experimental conditions

Orifice Sapphires 0.1 to 0.3 mm
Focussing Tube WC 0.8 to 2.4 mm
Pressure 2500 to 4000 bar
Abrasive garnet and olivine - #125 to #60
Abrasive flow - 0.1 to 1.0 Kg/min
Stand off distance 1 to 2 mm
Machine Impact Angle 60o to 900
Traverse Speed 100 mm/min to 5 m/min
Depth of Cut 1 mm to 250 mm

Abrasive Jet Machining

Modelling of material removal
Material removal in AJM takes place due to brittle fracture of the
work material due to impact of high velocity abrasive particles.
Modelling has been done with the following assumptions:
(i) Abrasives are spherical in shape and rigid. The particles are
characterized by the mean grit diameter
(ii) The kinetic energy of the abrasives are fully utilised in
removing material
(iii) Brittle materials are considered to fail due to brittle fracture
and the fracture volume is considered to be hemispherical with
diameter equal to chordal length of the indentation
(iv) For ductile material, removal volume is assumed to be equal
to the indentation volume due to particulate impact.

Process Parameters and

Machining Characteristics
Abrasive : Material Al2O3 / SiC / glass beads
Shape irregular / spherical
Size 10 ~ 50 m
Mass flow rate 2 ~ 20 gm/min
Carrier gas : Composition Air, CO2, N2
Density Air ~ 1.3 kg/m3
Velocity 500 ~ 700 m/s
Pressure 2 ~ 10 bar
Flow rate 5 ~ 30 lpm
Abrasive Jet : Velocity 100 ~ 300 m/s
Mixing ratio mass flow ratio of abrasive to gas
Stand-off distance 0.5 ~ 5 mm
Impingement Angle 600 ~ 900
Nozzle : Material WC
Diameter (Internal) 0.2 ~ 0.8 mm
Life 10 ~ 300 hours

Abrasive Jet Machining

effect of process parameters on MRR

Abrasive Jet Machining

In Abrasive Jet Machining (AJM), abrasive particles are made to impinge
on the work material at a high velocity. The high velocity abrasive particles
remove the material by micro-cutting action as well as brittle fracture of the
work material.

Advantages
o Extremely fast
o No

start hole

o There

is

o No

&

programming

required

only one

o Low capital
o Less

setup

tool

cost

vibration

heat

generated

o Environmentally

in

work

friendly

piece

Disadvantages
o

Low metal removal rate

Due to stay cutting accuracy is affected

Abrasive powder cannot be reused

Tapper is also a problem

Limitations
o The removal rate is slow.
o Stray cutting cant be avoided (low accuracy of 0.1 mm).
o The tapering effect may occur especially when drilling in metals.
o The abrasive may get impeded in the work surface.
o Suitable dust-collecting systems should be provided.
o Soft materials cant be machined by the process.
o Silica dust may be a health hazard.
o Ordinary shop air should be filtered to remove moisture and oil.
35

Conclusion
o The better performance , and the applications
represented above statements confirm that
ABRASIVE JET MACHINING is continue to
expand .
o The new softwares used to minimize time and
investments , there by making it possible for
more manufacturers of precision parts to install
AJM centers .