Abrasive jet machining

Prof. V.K. Saini

Fig : Schematic illustration of Abrasive Jet Machining

Introduction
It is one of the un conventional process
which depends on the concept of
mechanical erosion.
In this process a fine grained abrasives are
thrown over the work piece at a very high
speed. Generally used jet consists of
abrasives mixed with air (or) some other
carrier gases at high pressure.
In this process the material is removed by
the erosion caused due to the jet.

How does the abrasive jet

produce?
In abrasive jet machining jet is produced by mixing the gas

with abrasive particles.

The gas used is called as carrier gas. Some of the most
common carrier gases employed are air, carbon dioxide
nitrogen. Oxygen is never used as a carrier gas as it may
oxidize the surface of the work piece.
The carrier gas is first sent in to a compressive tank where
it is filtered and stored. The carrier gas is then sent in to the
mixing chamber when the jet is required to be generated.
In the mixing chamber the abrasive particles are finely
mixed with the carrier gas. Then the jet is released at the
required pressure.
In general the abrasives used are aluminum oxide, silicon
carbide, sodium bicarbonate.
When sodium bicarbonate is employed it should be dried
and cleaned properly before employing in the jet.
In general the abrasives used have a size ranges between
10 to 50 micron. Silicon carbide is used when faster cutting
is required on hard materials.

Mechanism of metal cutting in abrasive

jet machining
In this process the abrasive jet carrying
kinetic energy is focused on the work piece
the kinetic energy of the jet gets converted
in to pressure energy.
When this pressure energy is greater than
the ultimate tensile strength of the work
piece material then the material gets
eroded.
The nozzle is placed at a distance of
0.8mm for obtaining effective material
removal rate.

Advantages of abrasive jet machining

1) It is able to machine components which are
very brittle in nature and these cannot be
done by ordinary processes.
2) As the tool is not employed here heat
generation will be less (or) negligible.
3) Low capital consumption
4) Low power consumption
Limitations of abrasive jet machining
1) Metal removal rate is low
2) The abrasive particles may get embedded
in to the work piece
3) While drilling holes problem of tapering
may arise
4) Possibility of development of micro cracks

Applications of abrasive jet machining

Abrasive jet machining is effectively applied for processes like

For the removal of flash and parting lines in injection molded

castings
Plastic, nylon, Teflon components can be deburred and
polished.
Metallic mold cavities which are otherwise ineffective can be
cleaned by this process
Thin sectioned fragile components made of glass,
refractories, ceramics, mica etc. can be easily cut by using
this method
High quality surfaces can be easily produced.
Glue and paints can be removed effectively from paintings
and leather objects.
With the help of masks made of rubber, copper etc. designs
are reproduced over the surface of glass.
Interior surfaces of glasses can be frosted.
Markings on glass cylinders can be etched.

Factors influencing abrasive jet

machining
Various factors effecting abrasive jet
machining are
1) Carrier gas
2) Type of abrasive
3) Size of abrasive
4) Velocity of abrasive jet
5) Mean number of abrasive particles of
unit
volume of the carrier gas
6) Work material
7) Standoff distance
8) Nozzle design
9) Shape of cut

1) Carrier gas
The carrier gas should not excessively in to
the atmosphere. The gas should have some
properties like
a. Non-toxic
b. Easily available
c. Cheap
d. Drying and cleaning should not be difficult
Some of the most commonly used carrier
gases are air, carbon dioxide, nitrogen. Of all
air is most commonly used carrier gas. As its
properties satisfies the requirements of
carrier gas while using air Air filters should
be strictly employed.

2) Type of abrasive
Abrasives are selected according to type of
machining operation to be employed. The
abrasives should be having sharp and irregular
shapes and should be fine enough to get
suspended in the carrier gas. It should also have
excellent flow properties. Some of the most
commonly and frequently used abrasives for
cutting are
a. Aluminum carbide
b. Silicon carbide
And that for cleaning, etching, deburring and
polishing are silicon bicarbonate, dolomite, glass
beads etc. It is not recommended to re use the
abrasives which are already used as they may
affect the flow rate and cutting rate. In some
cases they tries to clog the nozzle.

3) Grain size
The rate of material removal rate is high and if it is
small then the cutting is small. If the small grain size is
used then they may stick together and there is a
possibility for chocking of nozzle. In general grains of
size ranging from 10 micron to 50 micron are used.
Coarse and fine grains are used for cutting where as
fine grains are used for polishing and deburring etc.
4) Standoff distance
It is the effective distance between the nozzle tip and
the work piece. It has a considerable affect on the rate
of material removal. If a small standoff distance is
maintained there is every chance of the penetration of
abrasive particles in to the work piece. If lager
standoff distance is maintained flaring may take place.
It is found from various experiments that the effective
standoff distance is 0.8mm

5) Jet velocity/ velocity of abrasive

jet
Metal removal by erosion uses the
kinetic energy of abrasive jet. The
velocity depends on the factors like
a. Nozzle pressure
b. Nozzle design
c. Size of abrasive grain
d. Mean number of abrasives per unit
volume of carrier gas

6) Mean number of abrasives per unit

volume of carrier gas
A value of mean number of abrasives
per unit volume of carrier gas can be
obtained by taking mixing ratio M. it
is given by the formula
M = ( volume flow rate of abrasive
per unit time )/( volume flow rate of
carrier gas per unit time )

7) Work material
Abrasive jet machining is generally used for
machining brittle materials like glass, ceramics etc.
The effective metal removal rate highly depends on
the hardness of work piece material. Ductile materials
are partially unmachinable by abrasive jet machining.
8) Nozzle design
Nozzle has to withstand various conditions like
erosive action of abrasive materials, pressure and
kinetic energy of jet. The most commonly used
materials for nozzle are sapphire, tungsten carbide.
Pressure losses at the end of nozzle should be very
low. Depending on the requirements the nozzle may
be designed either in rectangular or circular cross
sections

9) Shape of cut
Accuracy of machining may also be
dependent on the shape of cut. It is
not possible to machine the sharp
edges as there is a problem of micro
cracks.

High velocity abrasive gas jet (150 ~ 300 m/s)

nozzle

di (0.2 ~0.8 mm)

Stand off distance

(0.5 ~15 mm)

workpiece

MRR

MRR

Mixing ratio

Abrasive flow rate

MRR

MRR

Gas flow rate

For constant
mixing ratio

Abrasive flow rate

Gas pressure

MRR

Effect of process parameters MRR