AJM

Abrasive jet machining

From Wikipedia, the free encyclopedia
For the process that uses water as a carrier, see Water jet cutter.
Abrasive jet machining (AJM), also known as abrasive micro-blasting, pencil blasting and micro-abrasive blasting,
[1]
is an abrasive
blasting machining process that uses abrasivespropelled by a high velocity gas to erode material from the workpiece. Common uses include cutting
heat-sensitive, brittle, thin, or hard materials. Specifically it is used to cut intricate shapes or form specific edge shapes.
[2][3][4]

Contents
[hide]
1 Process
o 1.1 Equipment
2 Advantages and disadvantages
3 References
Process[edit]
Material is removed by fine abrasive particles, usually about 0.001 in (0.025 mm) in diameter, driven by a high velocity fluid stream; common gases are
air or inert gases. Pressures for the gas range from 25 to 130 psig (170900 kPag) and speeds can be as high as 300 m/s.
[2][3]

Equipment[edit]
AJM machines are usually self-contained bench-top units. First it compresses the gas and then mixes it with the abrasive in a mixing chamber. The gas
passes through a convergent-divergentnozzle before entering the mixing chamber, and then exits through a convergent nozzle. The nozzle can be
hand held or mounted in a fixture for automatic operations.
[2][3]

Nozzles must be highly resistant to abrasion and are typically made of tungsten carbide or synthetic sapphire. For average material removal, tungsten
carbide nozzles have a useful life of 12 to 30 hours, and sapphire nozzles last about 300 hours. The distance of the nozzle from the workpiece affects
the size of the machined area and the rate of material removal.
[3]

Grit size and orifice diameters for various abrasive materials
[3]

Abrasive material Grit size (in) Orifice diameter (in)
Aluminum oxide 10 - 50 0.005 - 0.018
Silicon carbide 25 - 50 0.008 - 0.018
Glass beads 2500 0.026 - 0.05
Advantages and disadvantages[edit]

This article contains a pro and con list. Please help improve it by integrating both sides into a
more neutral presentation. (November 2012)
The main advantages are its flexibility, low heat production, and ability to machine hard and brittle materials. Its flexibility owes from its ability to use
hoses to transport the gas and abrasive to any part of the workpiece.
[3][4]

One of the main disadvantages is its slow material removal rate; for this reason it is usually used as a finishing process. Another disadvantage is that
the process produces a tapered cut.
[3][4]

References[edit]
1. Jump up^ Applications, archived from the original on 03-04-2010, retrieved 09-02-2010.
2. ^ Jump up to:
a

b

c
Boothroyd, Geoffrey; Knight, Winston A. (1989), Fundamentals of machining and
machine tools (2nd ed.), Marcel Dekker, pp. 478479, ISBN 978-0-8247-7852-1.
3. ^ Jump up to:
a

b

c

d

e

f

g
Todd, Robert H.; Allen, Dell K.; Alting, Leo (1994), Manufacturing Processes
Reference Guide, Industrial Press Inc., pp. 25, ISBN 0-8311-3049-0.
4. ^ Jump up to:
a

b

c
Chastagner, Matthew W.; Shih, Albert J. (2007), "ABRASIVE JET MACHINING FOR
EDGE GENERATION", Transactions of NAMRI/SME 35: 359366.
Categories:
Abrasive blasting
Industrial processes
Machining
Navigation menu
Create account
Log in
Article
Talk
Read
Edit
View history

Main page
Contents
Featured content
Current events
Random article
Donate to Wikipedia
Wikimedia Shop
Interaction
Help
About Wikipedia
Community portal
Recent changes
Contact page
Tools
Print/export
This page was last modified on 29 January 2014 at 13:51.
Text is available under the Creative Commons Attribution-ShareAlike License; additional terms may apply. By using this site,
you agree to the Terms of Use and Privacy Policy.
Wikipedia is a registered trademark of the Wikimedia Foundation, Inc., a non-profit organization.
Privacy policy
About Wikipedia
Disclaimers
Contact Wikipedia
Developers
Mobile view





















Non Traditional Machining
Jagadeesha T, Assistant Professor. MED, National In
stitute of Technology, Calicut
ABRASIVE JET MACHINING
Definition:
In abrasive jet machining, a focused stream of abra
sive particles, carried by high
pressure air or gas is made to impinge on the work
surface through a nozzle and the
work material is made to impinge on the work surfac
e through a nozzle and work
material is removed by erosion by high velocity abr
asive particles.
Process:
In Abrasive jet machining abrasive particles are ma
de 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 conver
ting pressure energy of carrier
gas or air to its Kinetic energy and hence high vel
ocity jet. Nozzles directs 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 effectiv
ely 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 stand off distance of around 2mm. The kinetic ene
rgy 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 s
tream

The particle are directed towards the focus of mach
ining

As the particles impact the surface, it causes a mi
cro fracture, and gas carries
fractured particles away

Brittle and fragile work better
Non Traditional Machining
Jagadeesha T, Assistant Professor. MED, National In
stitute of Technology, Calicut
Equipment:
A schematic layout of AJM is shown above. The gas s
tream is then passed to the
nozzle through a connecting hose. The velocity of t
he abrasive stream ejected
through the nozzle is generally of the order of 330
m/sec.
Abrasive jet Machining consists of
1.
Gas propulsion system
2.
Abrasive feeder
3.
Machining Chamber
4.
AJM Nozzle
5.
Abrasives
Gas Propulsion System
Supplies clean and dry air. Air, Nitrogen and carbo
n dioxide to propel the abrasive
particles. Gas may be supplied either from a compre
ssor or a cylinder. In case of a
compressor, air filter cum drier should be used to
avoid water or oil contamination of
abrasive powder. Gas should be non-toxic, cheap, ea
sily available. It should not
excessively spread when discharged from nozzle into
atmosphere. The propellant
consumption is of order of 0.008 m
3
/min at a nozzle pressure of 5 bar and abrasive
flow rate varies from 2 to 4 gm/min for fine machin
ing and 10 to 20 gm/min for
cutting operation.
Abrasive Feeder.
Required quantity of abrasive particles is supplied
by abrasive feeder. The filleted
propellant is fed into the mixing chamber where in
abrasive particles are fed through
a sieve. The sieve is made to vibrate at 50-60 Hz a
nd mixing ratio is controlled by
the amplitude of vibration of sieve. The particles
are propelled by carrier gas to a
mixing chamber. Air abrasive mixture moves further
to nozzle. The nozzle imparts
high velocity to mixture which is directed at work
piece surface.
Non Traditional Machining
Jagadeesha T, Assistant Professor. MED, National In
stitute of Technology, Calicut
Machining chamber
It is well closed so that concentration of abrasive
particles around the working
chamber does not reach to the harmful limits. Machi
ning chamber is equipped with
vacuum dust collector. Special consideration should
be given to dust collection
system if the toxic material (like beryllium) are b
eing machined.
AJM nozzle
AJM nozzle is usually made of tungsten carbide or s
apphire ( usually life 300 hours
for sapphire , 20 to 30 hours for WC) which has res
istance to wear. The nozzle is
made of either circular or rectangular cross sectio
n and head can be head can be
straight, or at a right angle. It is so designed t
hat loss of pressure due to the bends,
friction etc is minimum possible. With increase in
wear of a nozzle, the divergence of
jet stream increases resulting in more stray cuttin
g and high inaccuracy.
Non Traditional Machining
Jagadeesha T, Assistant Professor. MED, National In
stitute of Technology, Calicut
ABRASIVES
Aluminum oxide (Al
2
O
3
) Silicon carbide (SiC) Glass beads, crushed glass
and sodium
bicarbonate are some of abrasives used in AJM. Sele
ction of abrasives depends on
MRR , type of work material , machining accuracy.
Abrasives Grain Sizes Application
Aluminum oxide(Al
2
O
3
) 12, 20, 50 microns Good for cleaning, cutting
and deburring
Silicon carbide (SiC) 25,40 micron Used for simila
r
application but for hard
material
Glass beads 0.635 to 1.27mm Gives matte finish
Dolomite 200 mesh Etching and polishing
Sodium bi carbonate 27 micros Cleaning, deburring
and
cutting of soft material
Light finishing below 50
0
C
Process parameters
For successful utilization of AJM process, it is ne
cessary 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 Al
2
O
3
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

Carrier Gas
a)
Composition Air, CO2, N2
b)
Density 1.3 kg/m
3
c)
Velocity - 500 to 700 m/s
d)
Pressure - 2 to 10 bar
e)
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)
Stand off distance SOD- 0.5 to 15mm.
e)
Impingement angle 60 to 90 deg.
Non Traditional Machining
Jagadeesha T, Assistant Professor. MED, National In
stitute of Technology, Calicut

Nozzle
a)
Material WC/Sapphire
b)
Diameter 0.2 to 0.8 mm
c)
Life 300 hours for sapphire, 20 to 30 hours for W
C
Process capability
1. Material removal rate 0.015 cm
3
/min
2. Narrow slots 0.12 to 0.25mm

0.12mm
3 Surface finish -0.25 micron to 1.25 micron
4 Sharp radius up to 0.2mm is possible
5. Steel up to 1.5mm ,Glass up to 6.3mm is possible
to cut
6. Machining of thin sectioned hard and brittle mat
erials is possible.
Applications
1.
This is used for abrading and frosting glass more e
conomically as compared to
etching or grinding
2.
Cleaning of metallic smears on ceramics, oxides on
metals, resistive coating etc.
3.
AJM is useful in manufacture of electronic devices
, drilling of glass wafers, de
burring of plastics, making of nylon and Teflon par
ts permanent marking on
rubber stencils, cutting titanium foils
4.
Deflashing small castings, engraving registration n
umbers on toughened glass
used for car windows
5.
Used for cutting thin fragile components like germa
nium, silicon etc.
6.
Register treaming can be done very easily and micro
module fabrication for
electrical contact , semiconductor processing can a
lso be done effectively.
7.
Used for drilling , cutting , deburring etching and
polishing of hard and brittle
materials.
8.
Most suitable for machining brittle and heat sensit
ive materials like glass, quartz,
sapphire , mica , ceramics germanium , silicon and
gallium.
9.
It is also good method for deburring small hole lik
e in hypodermic needles and
for small milled slots in hard metallic components.
Advantages
1. High surface finish can be obtained depending up
on the grain sizes
Particle size ( in microns) Surface roughness ( in
microns)
10
0.152 to 0.203
25 to 27 0.355 to 0.675
50
0.965 to 1.27
2. Depth of damage is low ( around2.5 microns)
3. It provides cool cutting action, so it can machi
ne delicate and heat sensitive
material
4.Process is free from chatter and vibration as the
re is no contact between the tool
and work piece
5.Capital cost is low and it is easy to operate and
maintain AJM.
6.Thin sections of hard brittle materials like germ
anium, mica, silicon, glass and
ceramics can be machined.
7.It has the capability of cutting holes of intrica
te shape in hard materials.
DESIGN AND FABRICATION
OF
ABRASIVE JET MACHINE


A THESIS SUBMITTED IN PARTIAL FULFILLMENT OF THE
REQUIREMENTS FOR THE DEGREE OF


Bachelor of Technology

In

Mechanical Engineering


KRUSHNA PRASAD PRADHAN
Roll 10503048




Department of Mechanical Engineering
National Institute of Technology
Rourkela
2009



DESIGN AND FABRICATION
OF
ABRASIVE JET MACHINE

A THESIS SUBMITTED IN PARTIAL FULFILLMENT OF THE
REQUIREMENTS FOR THE DEGREE OF

Bachelor of Technology

In

Mechanical Engineering

By
KRUSHNA PRASAD PRADHAN
Roll 10503048


Under the guidance of

Dr. C. K. BISWAS

Department of Mechanical Engineering
National Institute of Technology
Rourkela
2009

National Institute of Technology
Rourkela

CERTIFICATE




This is to certify that the thesis entitled DESIGN AND FABRICATION OF
ABRASIVE JET MACHINE Submitted by MR. KRUSHNA PRASAD
PRADHAN in partial fulfillment of the requirements for the award of Bachelor
of technology Degree in Mechanical Engineering at the National Institute of
Technology, Rourkela (Deemed University) is an authentic work carried out by
him under my supervision and guidance. To the best of my knowledge, the
matter embodied in the thesis has not been submitted to any other University /
Institute for the award of any Degree or Diploma.

DATE: Dr. C. K. BISWAS

NATIONAL INSTITUTE OF TECHNOLOGY
ROURKELA, 769008



ACKNOWLEDGEMENT

I deem it a privilege to have been a student of Mechanical Engineering streem in National
Institute of Technology, Rourkela. I take this opportunity to express my gratitude to all those
who motivated, encouraged and helped me in the project work. Im grateful to my
supervisor, Prof.C.K. Biswas, for his kind support, guidance and encouragement throughout
the project work, also for introducing to me this topic, which has been very interesting and
has given us great insight to the future work on this area. We would like to take the chance
to express our appreciation to our family members. Their continuous love and support gave
us the strength for pursuing our dream. Special thanks to our friends and other members of
the department for being so supportive and helpful in every possible way.

NIT Rourkela Krushna Prasad Pradhan
May 11, 2009 Roll No 10503048
Department of Mechanical Engineering
National Institute of Technology, Rourkela













CONTENTS
TITLE PAGENO.
PART ONE 4
1. Introduction 5
2. Equipment 5
3. Variables in Abrasive Jet Machine 7
4. Characteristics of different Variables 7
5. Advantages 8
6. Disadvantages 8
7. Application: 9
PART TWO 10
1. Literature survey: 11
PART THREE 17
1. DESIGN OF COMPONENTS
1. XY Table:
2. Ball Screw:
3. LMGuide or Linear Motion Guide Way:
4. Support Unit:
5. Nut Bracket:

18
18
22
25
30
31
1 | Page
2. ZAxis Assembly or Vertical Motion Module:
1. LM guide way:
2. Ball Screw & Support Unit
3. Nozzle
4. Limitations of Abrasive Jet nozzles:
32
33
34
35
37
3. TOTAL ASSEMBLY 38
4. Other Components
i. FRL unit
ii. Vibrating unit
a. Abrasive container
b. Cam
42
42
43
44
45
5. Cost Estimation 46
PART FOUR 47
1. Nozzle 48
2. Cam 49
3. Abrasive container 49
4. Vibrating assembly 50
CONCLUSION 51
BIBLIOGRAPHY & REFERENCES

52


2 | Page
A BSTRACT
Abrasive Jet Machining (AJM)isthe process ofmaterialremovalfroma workpiece by the
application of a high speed stream of abrasive particles carried in a gas medium from a
nozzle. The material removal process is mainly by erosion. The AJM will chiefly be used to
cut shapes in hard and brittle materials like glass, ceramics etc. the machine will be
automated to have 3 axes travel. The different components of AJM are Horizontal motion
module (XY Table), Vertical motion module (Z motion), Vibrator, dehumidifier, Pressure
Regulator, and Dust filter etc. The different components are selected after appropriate
design calculations.
In this project, a model of the Abrasive Jet Machine is designed using CAD packages like
AutoCAD, CATIA etc taking into consideration of commercially available components. Care
has been taken to use less fabricated components rather than directly procuring them,
because, the lack of accuracy in fabricated components would lead to a diminished
performance of the machine.











3 | Page
P a r t O n e








I N T R O D U C T I O N






4 | Page
1.1 Introduction
Abrasive Jet Machining (AJM)isthe removal ofmaterialfroma workpiece 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 deburring
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.
1.2 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 workpiece 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.
5 | Page

FIG1: SCHEMATIC LAYOUTOF ABRASIVE JET MACHINE


The major components are:
1. Air compressor.

2. Air filter.

3. Dehumidifier.

4. Pressure Gauge.

5. Pressure Regulator.

6. Vibrator or Mixer.

7. Nozzle.

8. Horizontal and Vertical motion module (for xyz motion).

9. Arrangement to hold the workpiece.




6 | Page
1.3 Variables inAbrasive Jet Machine:
The variablesthatinfluence the rate ofmetalremoval and accuracy ofmachining in this
process is:

1. Carrier gas

2. Types of abrasive

3. Size of abrasive grain

4. Velocity of abrasive jet

5. Flow rate of abrasive

6. Work material

7. Geometry, composition and material of nozzle

8. Nozzle work distance (stand off distance)

9. Shape of cut and operation type

1.3.1 Characteristics of different Variables:

Medium Air , CO2 ,N2
Abrasive SiC, Al2O3 (of size 20 to 50 )
Flow rate of abrasive 3 to 20 gram/min
Velocity 150 to 300 m/min
Pressure 2 to 8 kg/cm2
Nozzle size 0.07 to 0.40 mm
Material of nozzle WC, Sapphire
Nozzle life 12 to 300 hr
7 | Page
Stand off distance 0.25 to 15mm(8mmgenerally)
Work material Non Metalslike glass, ceramics, and granites.
Metals and alloys of hard materials like
germanium, silicon etc
part application Drilling, cutting, deburring, cleaning

TABLE1
1.4 Advantages:
1. Ability to cut intricate holes shape in materials of any hardness and brittleness.
2. Ability to cut fragile and heat sensitive material without damage.
3. No change in microstructure as no heat is generated in the process.
4. Low capital cost.
1.5 Disadvantages:
1. Material removal rate is low and hence its application is limited.
2. Stray strings can occur and hence its application is limited.
3. Embedding of the abrasive in the workpiece surface may occur while machining softer
material.
4. The abrasive material may accumulate at nozzle and fail the process if moisture is present in
the air.
5. It cannot be used to drill blind holes.
8 | Page

1.6 Application:
The major field of application of AJM process is in the machining of essentially brittle materials and
heat sensitive materials like glass, quartz, sapphire, semiconductor materials, mica and ceramics. It is
also used in cutting slot, thin sections, countering, drilling, deburring, for producing integrate shapes
in hard and brittle materials. It is often used for cleaning and polishing of plastics nylon and Teflon
components. Delicate cleaning, such as removal of smudges from antique documents, is also
possible with AJM.
































9 | Page
P A R T T W O









L I T E R A T U R E S U R V E Y






10 | Page
2.1 Literature survey:

The literature study of Abrasive Jet Machine reveals that the Machining process was
started a few decades ago. Till date there has been a through and detailed experiment and
theoretical study on the process. Most of the studies argue over the hydrodynamic
characteristics of abrasive jets, hence ascertaining the influence of all operational variables
on the process effectiveness including abrasive type, size and concentration, impact speed
and angle of impingement. Other papers found new problems concerning carrier gas
typologies, nozzle shape, size and wear, jet velocity and pressure, standoffdistance (SOD),
or nozzletipdistance (NTD). These papers express the overall process performance in terms
of material removal rate, geometrical tolerances and surface finishing of work pieces, as
well as in terms of nozzle wear rate. Finally, there are several significant and important
papers which focus on either leading process mechanisms in machining of both ductile and
brittle materials, or on the development of systematic experimentalstatistical approaches
and artificial neural networks to predict the relationship between the settings of
operational variables and the machining rate and accuracy in surface finishing.
(Ref17) Computational fluid dynamics (CFD) simulation of the formation and discharge
process of an airwater flow in an abrasive waterjet (AWJ) head is presented by Umberto
Prisco & Maria Carmina D'Onofrio. Numerical simulations have been conducted using the
commercial code Fluent 6.3 by Ansys. Dynamic characteristics of the flow inside the AWJ
head and downstream from the nozzle has been simulated under steady state, turbulent,
twophase flow conditions. The final aim is to gain fundamental knowledge of the ultrahigh
velocity flow dynamic features that could affect the quality of the jet, such as the velocity
and pressure distributions in different parts of the AWJ head and at the outlet.
11 | Page
(Ref20) Experiments have been performed on effect ofjet pressure, abrasive flow rate
and work feed rate on smoothness ofthe surface produced by abrasive waterjetmachining
of carbide of grade P25. Carbide of grade P25 is very hard and cannot be machined by
conventional techniques. The abrasive used in investigations was garnet of mesh size 80. It
was tried to cut carbide with low and medium level of abrasive flow rate, but the jet failed
to cut carbide since it is too hard and very high level of energy is required. Minimum rate of
abrasive flow that made it possible to cut carbide efficiently was 135 g min1
. With increase
in jet pressure the surface becomes smoother due to higher kinetic energy of the abrasives.
But the surface near the jet entrance is smoother and the surface gradually becomes
rougher downwards and is the roughest near the jet exit. Increase in abrasive flow rate also
makes the surface smoother which is due to the availability of higher number of cutting
edges per unit area per unit time. Feed rate didnt show significant influence on the
machined surface, but it was found that the surface roughness increases drastically near the
jet entrance.

The study of the results of machining under various conditions approves that a
commercial AJM machine was used, with nozzles of diameter ranging from 0.45 to 0.65 mm,
the nozzle materials being either tungsten carbide or sapphire, both of which have high tool
lives. Silicon carbide and aluminum oxide were the two abrasives used. Other parameters
studied were nozzle tip distances (510 mm), spray angles (60 and 90) and pressures (5
and 7 bars) for materials like glass, ceramics, and electrodischarge machined (EDM) die
steel. The holes drilled by AJM may not be circular and cylindrical but almost elliptical and
12 | Page
bell mouthed.Highmaterialremovalrate conditions do not necessarily yield small narrow
cleancut machined areas.
(Ref16)
Studies reveal that AJM is an attractive micromachining method for ceramic
materials. The machinability during the AJM process can be compared to that given by the
established models of solid particle erosion, in which the material removal is assumed to
originate in the ideal crack formation system. However, it was clarified that the erosion
models are not necessarily applicable to the AJM test results, because the relative hardness
of the abrasive against the target material, which is not taken into account in the models, is
critical in the micromachining process. No strength degradation took place for the AJM
ceramic surfaces. This is attributed to the fact that radial cracks did not propagate
downwards by particle impacts during the machining process.
(Ref14)
Abrasive WaterJet (AWJ) turning is a technology that still tries to find its niche
field of application where it can be economically viable. But a particular application of AWJ
turning has proved its technological and economical capability, i.e. profiling and dressing of
grinding wheels. Starting from the theoretical considerations, the key operating parameters
of AWJ turning are identified and included in a methodology to generate various profiles of
grinding wheels by means of tangential movement of the jet plume. Roughing in single pass
to concave/convex geometries (experimented depth of cuts < 30 mm), generation of thin
walls/slots (thickness < 2 mm, depth > 430 mm) and intricate profile (e.g. succession of tight
radii) on a variety of grinding wheels show the capability of AWJ turning to fulfill the
requirements of this niche application.
The machining process produces no heat and hence changes in microstructure or
strength of the surface is unlikely. The air acts as a coolant and hence AJM process has a
13 | Page
high potential as damage freemicromachiningmethod. The fracture toughness and
hardness ofthe targetmaterials are critical parameters affecting thematerialremovalrate
in AJM. However, their influence on the machinability varied greatly with the employed
abrasives.
In recent years abrasive jet machining has been gaining increasing acceptability for
deburring applications. The influence of abrasive jet deburring process parameters is not
known clearly. AJM deburring has the advantage over manual deburring method that
generates edge radius automatically. This increases the quality of the deburred
components. The process of removal of burr and the generation of a convex edge were
found to vary as a function of the parameters jet height and impingement angle, with a fixed
SOD. The influence of other parameters, viz. nozzle pressure, mixing ratio and abrasive size
are insignificant. The SOD was found to be the most influential factor on the size of the
radius generated at the edges. The size of the edge radius generated was found to be
limited to the burr root thickness.
(Ref15)
Abrasive jet finishing combined with grinding gives rise to a precision finishing
process called the integration manufacturing technology, in which slurry of abrasive and
liquid solvent is injected to grinding zone between grinding wheel and work surface under
no radial feed condition. The abrasive particles are driven and energized by the rotating
grinding wheel and liquid hydrodynamic pressure and increased slurry speed between
grinding wheel and work surface achieves micro removal finishing.
Abrasive waterjet machines are becoming more widely used in mechanical
machining. These machines offer great advantages in machining complex geometrical parts
14 | Page
in almost anymaterial. This ability tomachine hardtomachine materials, combined with
advancements in both the hardware and software used in waterjetmachining, has caused
the technology to spread and become more widely used in industry. New developments in
high pressure pumps provide more hydraulic power at the cutting head, significantly
increasing the cutting performance of the machine. Analysis of the economic and technical
has been done by researchers. Those technology advancements in applying higher power
machining and intelligent software control have proven to significantly improve the overall
performance of the abrasive waterjet machining operation, thus widening the scope of
possible applications of this innovative and promising technology.
(Ref21)
Quality of the surface produced during abrasive water jet machining of
aluminum has been investigated in recent years. The type of abrasive used was garnet of
mesh size 80. The cutting variables were standoff distance of the nozzle from the work
surface, work feed rate and jet pressure. The evaluating criteria of the surface produced
were width of cut, taper of the cut slot and work surface roughness. It was found that in
order to minimize the width of cut; the nozzle should be placed close to the work surface.
Increase in jet pressure results in widening of the cut slot both at the top and at exit of the
jet from the work. However, the width of cut at the bottom (exit) was always found to be
larger than that at the top (at a standoff distance of 3 mm and the work feed rate of 15 mm
min1). It was found that the taper of cut gradually reduces with increase in standoff
distance and was close to zero at the standoff distance of 4 mm (at a jet pressure of 30 ksi
and a work feed rate of 15 mm min1). The feed rate of the work should be kept within 40
mm min1 (at the jet pressure of 30 ksi and the standoff distance of 3 mm), because a feed
rate beyond 40 mm min1 results in sharp increase in taper angle. The jet pressure does not
15 | Page
show significantinfluence on the taper angle within the range of work feed and the stand
off distance considered. Both standoff distance and the work feed rate show strong
influence on the roughness of the machined surface. Hence standoff distance should be
kept within 3 mm (at a jet pressure of 30 ksi and a work feed rate of 15 mm min1) and the
work feed rate should be kept within 30 mm min1 (at a jet pressure of 30 ksi and a stand
off distance of 3 mm) in order to have a good surface finish, since beyond those values of
the parameters the roughness of the machined surface rises sharply. Increase in jet pressure
shows positive effect in terms of smoothness of the machined surface. With increase in jet
pressure, the surface roughness decreases (at a standoff distance of 3mm and work feed of
15 mm min1). This is due to fragmentation of the abrasive particles into smaller sizes at a
higher pressure and due to the fact that smaller particles produce smoother surface. So
within the jet pressure considered, the work surface is smoother near the top surface and
gradually it becomes rougher at higher depths.











16 | Page
P a r t T h r e e








D E S I G N O F C O M P O N E N T S








17 | Page
3.1 DESIGN OF COMPONENTS
3.1.1 X-Y Table:
XY table is the most important part of the AJM over which the workpiece has to be kept and
machined. The travel of XY table has been decided to be 400 x 350 mm.
The different components of the XY table are:
1. LM guideway (2 pairs4 nos.)
2. Ball screw (2 nos.)
3. Support unit (2 fixed & 2 supported)
4. Nut bracket (2 nos.)
5. Couplings (2nos.)
6. Standard nuts and bolts.
7. Other components (to be manufactured in the lab).
The XY table consists of two parts: (a) Upper table, (b) Lower table. The upper table is responsible
for x movement and has a travel of 400 mm. The lower table has a travel of 350 mm and is
responsible for the y motion of the workpiece.
The different diagrams of the assembled views along with dimensions have been shown below.

18 | Page


FIG2: XY TABLE ASSEMBLY (ISOMETRIC VIEW)
19 | Page

FIG3: XY TABLE ASSEMBLY (2D VIEWS)
20 | Page

FIG4: XY TABLE (TOP VIEW)

FIG5: XY TABLE (SIDE VIEW)
21 | Page
3.1.2 Ball Screw:
Ball screw issimilarto lead screw superficially butthe friction is greatly reduced in case of ball
screws by inserting recirculating balls inbetween the screw thread and the nut. The thread profile is
made circular and the nut thread has got a reverse shape which forms a spiral cavity inside which the
balls move when the nut is rotated. Once the balls reach the end of the nut they are again
recirculated by means of a return pipe. Ball screws can preloaded or nonpreloaded. The accuracy
increases in case of preloaded type of ball screw as two sets of balls are pressed toward each other
thereby making the radial clearance close to zero.

FIG6: RECIRCULATING BALL SCREW




22 | Page
Screw length calculation:
Travel of XY table has been decided to be 400 x 350mm.
So screw of x axis ball screw:
= 400mm + 200mm + 100mm
(Travel) (Upper table breadth) (Allowance for bellows cover)
= 700mm.

Screw length yaxis ball screw:

= 350mm + 200mm + 100mm
(Travel) (Upper arrangement) (Bellows cover allowance)
= 650mm.
Commercial Ball screws are available from companies like (1) THK, (2) Grampus Impex Ltd., (3)
Precision Bearing House, and (4) ABBA etc.

The specifications by companies that satisfy our requirement are:
BNF2005 5 RR G2 850L 700 C7 (by THK Company)
BNF model no.
20 screw shaft diameter
05 lead
RR labyrinth seal attached
G2 axial clearance grade
850L overall shaft length (in mm)
700 screw length
C7 accuracy symbol
23 | Page
SFI2005 C7 800 650 P0
SFI model no. (Single nut)
20 screw shaft diameter
05 lead
C7 accuracy grade
800 total length
650 screw length
P0 precision level


FIG7: SCREW THREAD


24 | Page
FIG8: BALL SCREW ASSEMBLY (SHOWINGDIMESIONS AND MACHINED ENDS)



3.1.3 LM-Guide or Linear Motion Guide Way:
LMGuide as the name suggests is used for highly precise linear motion. It can sustain high loads in
any direction and hence can be mounted in any direction. The assembly contains a rail which guides
a block on it. Inside the block, ball or roller are present which drastically reduces the frictional losses.
So LMGuide is preferred in both industries and robotics to achieve specific functions.


FIG9: LM GUIDE ASSEMBLY

25 | Page
Structure and Features:
Balls roll in four rows of raceways precisionground on an LM rail and an LM block, and endplates
incorporated in the LM block allow the balls to circulate. Since retainer plates hold the balls, they do
not fall off even if the LM rail is pulled out (except models HSR 8, 10 and 12). Each row of balls is
placed at a contact angle of 45so that the rated loads applied to the LM block are uniform in the
four directions (radial, reverseradial and lateral directions), enabling the LM Guide to be used in all
orientations. In addition, the LM block can receive a wellbalanced preload, increasing the rigidity in
the four directions while maintaining a constant, low friction coefficient. With the low sectional
height and the high rigidity design of the LM block, this model achieves highly accurate and stable
linear motion.
4way equal load

FIG10: LOAD ON LM BLOCK
Each row of balls is placed at a contact angle of 45so that the rated loads applied to the LM block
are uniform in the four directions (radial, reverseradial and lateral directions), enabling the LM
Guide to be used in all orientations and in extensive applications
Highrigidity type
Since balls are arranged in four rows in a wellbalanced manner, a large preload can be applied and
the rigidity in four directions can easily be increased
26 | Page
High durability
Even under a preload or biased load, differential slip of balls does not occur. As a result, smooth
motion, high wear resistance, and longterm maintenance of accuracy are achieved.

Rated Loads in All Directions

Model HSR is capable of receiving loads in all four directions: radial, reverseradial and lateral
directions. The basic load ratings are uniform in the four directions (radial, reverseradial and lateral
directions), and their actual values are provided in the dimensional table for HSR.

Equivalent Load

When the LM block of model HSR receives loads in the reverseradial and lateral directions
simultaneously, the equivalent load is obtained from the equation below
PEPRPLPT
Where
PE Equivalent load (N)
Radial direction
Reverseradial direction
Lateral direction
PR Radial load (N)
27 | Page
PL Reverseradial load (N)
PT Lateral load (N)



Advantage of LM Guide
1. Smooth movement with no clearance.
2. High running precision with ease.
3. High rigidity in all direction.
4. High permissible load rating.
5. High long term precision.
6. High speed operation.
These combine to give rise
1. Low total cost.
2. High precision in machines incorporating the LM guide.
3. High productivity in the same.
4. Substantial energy saving.
5. High efficiency in machine design.
6. Simple maintenance.



28 | Page
Rail length calculation:
Length ofrailshould be approximately 50mmlargerthan that of corresponding ballscrew.
Hence in X axis: rail length = 750 mm.
Y axis: rail length = 700 mm.
LM Guides are commercially available from companies like (1) THK, (2) Grampus Impex Ltd., (3)
Precision Bearing House, and (4) ABBA etc.

The specification by companies that satisfy our requirement is:
HSR 30 R2 SS C5 700L H II

HSR model no.
30R size specification
2 2 blocks per rail
SS end seal + side seal
C5 radial clearance
700L standard length
H accuracy grade
II 2 rails

29 | Page

FIG11: DIMENSIONS OF LM GUIDE
3.1.4 Support Unit:

FIG12: SUPPORT UNIT
Support units are required for supporting the ballscrew ends. These are special kind of bearings
which gives longer service life and better performance. They are of 2 types,
1. Fixed end support unit,
2. Supported end support unit.
In fixed end the support unit acts like a thrust bearing and takes all the thrust given by the work
load. In the supported end the support unit just acts like simple bearing.
30 | Page
Various types ofsupported units are available commercially. They differmainly in themannerthey
need to be fixed or bolted to a wall or ametal plate. Accordingly the fixing holes are provided on the
face or sides of the support unit.
Support units available commercially by THK are type EK for fixed side and FK for supported side.

FIG13: SUPPORT UNIT (DESIGN EF)
3.1.5 Nut Bracket:
Nut bracket is used to bolt the ball screw nut with the work load platform. Following diagram shows
a nut bracket along with a ball screw nut.

FIG14: NUT BTACKET
31 | Page
3.2 Z-Axis Assembly orVertical Motion Module:
Vertical motionmodule isrequired for adjusting the nozzle height orstand off distance fromthe
workpiece. When different operations are to be carried out, the set up time between operations can
be eliminated if the nozzle tip is raised to a height more than 5 cm. At this distance the abrasive jet
has negligible erosion effect on the workpiece. Hence the total Z motion has been decided to be
100mm.
The different components of the Vertical motion module are:
1. LM guide way (1 no.)
2. Ball screw (1 no.)
3. Support unit (1 fixed & 1 supported)
4. Couplings (1 no.)
5. Nozzle (1 no.)
6. Standard nuts and bolts.
7. Other components (to be manufactured in the lab).
The assembly view is shown in the next page.

32 | Page

Support unit
Pipe holder Ballscrew
LM Guide
Nozzle holder
Nozzle
Support unit
FIG15: VERTICAL MOTION MODULE


3.2.1 LM guide way:
The LM Guide selected is of the type HSRYR. The special feature of HSRYR is that the tapped holes
are present on the side of the LM Block and hence they can be attached to the load component from
the side.
33 | Page


FIG16: LM Guide (type HSRYR)
3.2.2 Ball Screw & Support Unit
The ball screw selected for the Z axis assembly is of the type BNT. The support units are EK and FK
for fixed end and supported end respectively. The smaller space in the Zassembly doesnt allow for
the use of a nut bracket for the ball screw nut. So the BNT type ball screw has been selected from
THK catalogue as it has tapped holes on the nut itself which can be screwed to the load directly.

FIG17: BALL SCREW AND SUPPORT UNIT
34 | Page
3.2.3 Nozzle:
The abrasive particles are directed into the work surface at high velocity through nozzles. Therefore,
the material of the nozzle is subjected to great degree of abrasion wear and hence these are made
of hard materials such as tungsten carbide or synthetic sapphire. Tungsten carbide nozzles are used
for circular crosssections in the range of 0.120.8 mm diameter, for rectangular sections of size 0.08
x 0.05 to 0.18 x 3.8 mm and for square sections of size upto 0.7 mm. Sapphire nozzles are made only
for circular crosssections. The size varies from 0.2 to 0.7 mm diameter. Nozzles are made with an
external taper to minimize secondary effects due to ricocheting of abrasive particles. Nozzles made
of tungsten carbide have an average life of 12 to 30 hours while nozzles of sapphire last for about
300 hour of operation when used with 27 m abrasive powder.
The rate of material removal and the size of machined area are influenced by the distance of the
nozzle from the workpiece. The abrasive particles from the nozzle follow a parallel path only for a
short distance and then the jet flares resulting in the oversizing of the hole. It is observed that the jet
stream is initially a cylinder for about 1.6 mm and then it flares into a cone of 7 included angle. The
material removal rate initial increases with increase in the distance of the nozzle from the workpiece
because of the acceleration of particles leaving nozzle. This increase is maximum up to a distance
about 8 mm and then it steadily drops off because of increase in machining area for the same
amount of abrasive and decrease in velocity of abrasive stream due to drag.
35 | Page
FIG18: NOZZLE



Stand off
distance

Nozzle tip
Work piece
FIG19: Abrasive action of particles












36 | Page
3.2.4 Limitations ofAbrasive Jetnozzles:
Despite theirsimple design, abrasive jet nozzles can be troublesome attimes. There aremany designs,
but
they share the same problems:

1. Short life of an expensive wear part
2. Occasional plugging of mixing tube: Usually caused by dirt or large particles in abrasive.
3. Wear, misalignment, and damage to the jewel.













37 | Page
3.3 TOTAL ASSEMBLY
The assembly drawing ofthe abrasive jetmachine can be represented asfollows. It can be noted
that the components like air compressor, vibrator, dehumidifier, bellows cover and piping have not
been shown in the drawing

FIG20: SIDE VIEW OF WHOLE ASSEMBLY
38 | Page


FIG21: AJM FRONT VIEW
39 | Page

FIG22: AJM TOP VIEW
40 | Page

FIG23: AJM ISOMETRIC VIEW
41 | Page
3.4 Other Components
3.4.1 FRL Unit (Dehumidifier):
The FRL Unit (Air Filter Regulator Lubricator unit) which is otherwise called the moisture separator or
dehumidifier is required for separating the moisture from air. Atmospheric air always contains some
water vapour in it. As the air with high velocity is blown from the nozzle there is an abrupt rise in
pressure which converts water vapour into moisture. The moisture makes the abrasive particles to
agglomerate and this clogs the outlet of the Nozzle. To avoid this clogging moisture separator should
be used before abrasive particles are mixed with compressed air. Different FRL Units are available
commercially.

Inlet
Outlet
Circulation of Air
Chemicalsfor separating moisture
FIG24: FRL Unit
42 | Page
3.4.2 The VibratingUnit:
Vibrating Unitis used formixing the air with the abrasive particles(Al2O3). The Abrasive
particles are stored in a container through which air is flown. The particles are agitated by
means of a cam and motor arrangement. The rotation of cam results in vibration in the
abrasive container. The flow rate of abrasive materials can be controlled by manipulating
the rotational speed of the motor. The abrasive container will have one inlet and one outlet
for air passage and will be vertically suspended from a hinged joint.
So the Vibrating Unit consists of following parts
1. Motor (Induction type)
2. Cam
3. Abrasive container








43 | Page
Abrasive Container:

FIG 25: The Abrasive Container.





44 | Page
Cam:
Cam isfixed with shaft ofthe inductionmotor. The profile ofthe camistaken to be a circular
one. The distance between two centers as shown in fig26 is 3mm. When the motor rotates; it
makes the container to vibrate. Width of cam is 25mm.

FIG26: Cam






45 | Page
3.3.5 Approximate Cost Estimation:
TABLE: 2 (Cost estimation)
SL NO. NAME OF THE ITEM COST PER SINGLE
PIECE
NO. OF ITEMS
REQUIRED
TOTAL COST
FOR THE ITEM
1 Recirculating ball screw
X axis
Y axis
Z axis

Rs. 10,000.00
Rs. 7,000.00
Rs. 5,000.00

1
1
1


Rs. 22,00.00

2 Linear Motion guide ways
X axis
Y axis
Z axis

Rs. 17,000.00
Rs. 14,000.00
Rs. 6,000.00

1 pair
1 pair
1


Rs. 37,000.00
3 Support Unit
X axis ball screw
Y axis ball screw
Z axis ball screw

Rs. 3,000.00
Rs. 2,500.00
Rs. 2,500.00

2
2
2


Rs.16,000.00
4 FRL Unit Rs. 2,500.00 1 Rs. 2500.00
5 Vice Rs. 2,000.00 Rs. 2,000.00
6 Angles Rs. 1000.00 Rs. 1000.00
7 Other accessories Rs. 7,500.00
TOTAL Rs. 88,000.00


46 | Page
P a r t F o u r









F A B R I C A T I O N A N D A S E M B L I N G





47 | Page
4.1 Nozzle:
A standard MS cylindrical rod was cut into required length by power hacksaw. The external
diameter was then brought to 16mm by turning it in lathe and then the tip was made by tapering
one end by the same lathe. A blind hole of approximate depth 20mm was made on the planner face
of the rod by means of a 12mm drill bit in a drilling machine. The end of the blind hole forms a shape
of 118 degree taper because of the tool tip angle. Internal threading was made by 12mm tap. Then
the tip of the nozzle was made by drilling it by a 0.74mm diameter drill bit to get approximate
diameter of 1mm.

FIG 27: Nozzle


48 | Page
4.2 CAM:
Mild steel of diameter 40mmwastaken asrawmaterialforthis operation. Atfirstturning was done
in a lathe to bring down the diameter to 35mm. Then the required width (25mm) was cut by power
hacksaw and both the cut faces were machined in a milling machine. Then a through hole was made
by a 16mm drill bit in a drilling machine. The center offset was taken to be 3mm.
4.3 ABRASIVE CONTAINER:
The abrasive container was made out of a hollow cylinder. Two iron plates were welded on both
ends of the container. On the top plate two holes were drilled and iron pipes were fitted with these
holes. The inlet iron pipe is longer so as to make more agitation of the abrasive particles. The outlet
pipe is shorter. Both the pipes are clamped with nylon pipes which carries air through them. After
removal of moisture by the FRL unit the compressed air goes to abrasive container through inlet,
mixes with abrasive particle and then the air with abrasive particles moves through the nozzle to
perform the machining action.






49 | Page
4.5 THE VIBRATORASSEMBLY:
The angle section was welded with base plate by arc welding. A rod was welded with angle orienting
it parallel with base plate. An induction motor was placed on the base plate by tighten with nut bolt.
Cam was fixed with motor shaft. Then abrasive container was connected to the rod by means of the
holder. The container is free to rotate around the rod.


FIG 28: The vibrator assembly

50 | Page
CONCLUSION
In this project a complete design ofthe Abrasive Jet Machine is given. The XYZmotion
modules are designed taking in account of currently available components in the market.
The designing and assembling of very large number of components was a tremendous task
and was completed on time. However because of some parts couldnt be purchased the
whole assembly was limited to drilling operation.
The project can go beyond its current position and capabilities by employing automation
into it. This can be done by using stepper motors or DC servo motors interfaced with
standard PCI controllers or standalone controllers. 2D profiles can be converted into
standard Gcodes and Mcodes and that can be sent to the machine to perform automated
machining.







51 | Page
Bibliography & References
BOOKS
1. Production technology, HMT publication.
2. Elements of workshop technology, S K Hajra Choudhury, S K Bose, A K Hajra
choudhury, Niranjan Roy, VolII, Media promoters and media publications
3. Modern machining process, S Pandey and H N Shah, S. Chand and co.

WEBSITES

4. www.scopus.com
5. www.science direct .com.
6. www.maharashtradirectory.com
7. www.grampusimpex.com
8. www.thk.co.in
9. www.apex.com
10. www.elgi.com
11. www.indiamart.com

JOURNALS
12. Residual stress and tribological characteristics of ground surface after abrasive jet
restricted by grinding wheel
Authors: Liu, F., Gong, Y.D., Shan, Y.Q., Cai, G.Q.
Publication: Journal of Northeastern University, Volume 30, Issue 3, Pages 422425
March 2009.
13. Simulation and analysis of abrasive jet machining with wheel restriction in grinding
Authors: Wang, W.S., Zhu, L.D., Yu, T.B., Yang, J.Y., Tang, L.
Publication: Key Engineering Materials, Volume 389390, Pages 387391,
2009

52 | Page
14. Abrasive waterjetturningAn efficientmethod to profile and dress grinding wheels
Authors: D.A. Axinte,J.P. Stepanian, M.C. Kong,J. McGourlay
Publication: International Journal of Machine Tools and Manufacture, Volume 49,
Issues 34, March 2009, Pages 351356
Date: Dec, 2008

15. Modeling and simulation for material removal in abrasive jet precision finishing with
wheel as restraint.
Authors: Li, C.H., Ding, Y.C., Lu, B.H.
Publication: Proceedings of the IEEE International Conference on Automation and
Logistics, ICAL 2008, Article number 4636666, Pages 28692873, 2008

16. Abrasive jet micromachining of planar areas and transitional slopes
Authors: Ghobeity, A.; Spelt, J. K.; Papini, M.
Publication: Journal of Micromechanics and Microengineering, Volume 18, Issue 5,
pp. 055014.
Publication Date: 01/ 05/2008

17. ThreeDimensional CFD Simulation of TwoPhase Flow Inside the Abrasive Water Jet
Cutting Head
Authors: Umberto Prisco; Maria Carmina D'Onofrio.
Publication: International Journal of Computational Methods in Engineering Science
and Mechanics 9 (5), pp. 300319
Publication Date: 01 September 2008
18. Machinability of glass by abrasive waterjet
Authors: Zhu, H.T., Huang, C.Z., Wang, J., Lu, X.Y. and Feng, Y.X.
Publication: International Journal of Materials and Product Technology, Vol. 31,
No.1, pp.106112, 2008.



53 | Page
19. Surface evolutionmodelsfor abrasive jetmicromachining of holesin glass and
polymethylmethacrylate (PMMA)
Authors: Ghobeity, A.; Getu, H.; Papini, M.; Spelt, J. K.
Publication: Journal of Micromechanics and Microengineering, Volume 17, Issue 11,
pp. 21752185 (2007).
Date: 11/2007

20. Surface Roughness of Carbides Produced by Abrasive Water Jet Machining
Authors: Khan, Ahsan Ali; Awang, Mohd Efendee Bin; Annuar, Ahmad Azwari Bin
Publication: Journal of Applied Science, vol. 5, Issue 10, p.17571761
Date: 06/2005

21. A Study on Abrasive Water Jet Machining of Aluminum with Garnet Abrasives.
Authors: Khan, Ahsan Ali; Munajat, Noraziaty Bt.; Tajudin, Harnisah Bt.
Publication: Journal of Applied Science, vol. 5, Issue 9, p.16501654
Date: 01/2005
22. Effect of workpiece properties on machinability in abrasive jet machining of ceramic
materials
Authors: M. Wakuda, Y. Yamauchi and S. Kanzaki
Publication: Precision Engineering, Volume 26, Issue 2, April 2002, Pages 193198
23. An experimental study on the abrasive jet deburring of crossdrilled holes
Authors: R. Balasubramaniam, J. Krishnan and N. Ramakrishnan
Publication: Journal of Materials Processing Technology, Volume 91, Issues 13, 30
June 1999, Pages 178182

24. A study on the shape of the surface generated by abrasive jet machining
Authors: R. Balasubramaniam, J. Krishnan and N. Ramakrishnan
Publication: Journal of Materials Processing Technology, Volume 121, Issue 1, 14
February 2002, Pages 102106


54 | Page
55 | Page

25. Abrasive jet machining of glass at low temperature
Authors: M. K. Muju and A. K. Pathak
Publication: Journal of Mechanical Working Technology, Volume 17, August 1988,
Pages 325332

26. An experimental study of abrasive jet machining
Authors: A. P. Verma and G. K. Lal
Publication: International Journal of Machine Tool Design and Research, Volume 24,
Issue 1, 1984, Pages 1929




Explore


Upload
Go Pro
Login
Signup
Ads by safesaver. More Info | Hide These Ads
Email
Like
Save
Embed




















1
/18
Share
Ads by safesaver. More Info | Hide These Ads
Related
Abrasive water jet machining 93 views Like
Fy3310631066 129 views Like
phonetics 72 views Like
Nanofinishing 1877 views Like
Theoretical and graphical analysis of abrasivewater jetturning
74 views Like
Final evaluating materialremoval 61 views Like
N A ROBSON BROCHURE 727 views Like
KMT Waterjet Systems Stone Cutting Presentation 5834 views Like
KMT Waterjet Systems Metal Cutting Presentation 7894 views Like
Waterjet cutting milling 127 views Like
Blasting Cabinet byKrishna engineers 127 views Like
WATER JET CUTTING 1929 views Like
37624 _advanced_machining_processes.mcgraw-
hill_._2005.isbn0071453342_ 6500 views Like
Ef25803806 190 views Like
Final tech forum abrasives 181 views Like
Cl34527530 434 views Like
8 cuft classic-blast-machine 427 views Like
SandBlasting Products 184 views Like
Asm metals handbook volume 5 surface engineering 1003 views Like
N55 massarsky rev 268 views Like
Effect of Temperature on Wear Rate of Si-Epoxy- Eglass Polymer
composite Materia 60 views Like
Afp sme-turbo-finish 378 views Like
Analysis of abrasive jet machining parameters on mrr and kerf width
of hard and 689 views Like
Effect of the process parameters on the surface roughness during
magnetic 220 views Like
15ap2 176 views Like
Dental Materials: Properties & Manipulation, 10/e 1771 views Like
Mesin sandblasting clemco 623 views Like
Water jet cutting technology 2501 views Like
Flow wintech presentation 350 views Like
October 2013 f2 deburring 1 205 views Like
Flow Water Jet Cutting Machine Supplier, Manufacturer, Ahmedabad
117 views Like
Micromachining using an abrasive jet 855 views Like
Investigations on Wear by Slurry Abrasion of Hardfaced Low Alloy
Steel 310 views Like
Water jet manual 229 views Like
Follow
Presentation of-abrasive-jet-machining
by Amol Ranvare, Working at Student on J an 07, 2012
8,484 views
DFDFF
1 comment
11 of 1 comment
Manish Chander TANX.. ya its very helpful ... :) 1 year ago

Subscribe to comments Post Comment
2 Likes
pranavas 11 months ago
shivashree 11 months ago
Presentation of-abrasive-jet-machining
Presentation Transcript
WHAT IS1. It is the material removal process where theABRASIVE JET
MACHINING ? material is removed by high velocity stream of air/gas or water and An
abrasive is small, hard particle having sharpabrasive mixture . High velocity jet is
aimed at a surfaceedges and an irregular shape . under controller condition .
Motion system Mixing tube Nozzle Pump Control system Abrasivedelivery
system COMPONENTS OF ABRASIVE JETMACHINING2.
3. 1. ABRASIVE DELIVERY SYSTEMAuto 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 .
The4. 2.CONTROL SYSTEM control algorithm that computes exactly how the feed
rate should vary for a given geometry in a given material to make a precise Thepart .
algorithm actually determines desired variation in the feed rate & the tool path to provide
an extremely smooth feed rate .
5. Crankshaft3.PUMP & intensifier pump are mainly use in the The intensifier pump
was the only pump capableabrasive jet machine . Crankshaft pumps are moreof
reliably creating pressures high . efficient than intensifier pumps because they do not
require a power robbing hydraulic system ultra high pressure & more stroke per minute .
All abrasive jet systems use the same6. 4.NOZZLE basic two stage nozzle . First ,
water passes through a small diameter jewel orifice to form a narrow The abrasive
particles arejet . accelerated by the moving stream of water & they pass into a long
hollow cylindrical Generally two type of nozzleceramic mixing tube. use , right angle
head & straight head .
FIG. OF NOZZLE7.
8. The mixing tube is where the abrasive mixes5. MIXING TUBE with the The
mixing tube should be replaced whenhigh pressure water . For maximum accuracy
,tolerances drop below acceptable levels . replace the mixing tube more frequently .
9. 6.MOTION SYSTEM In order to make precision parts , an abrasive jet system must
have a precision x-y table and Tables fall into threemotion control system . Integrated
Floor-mounted gantry systemsgeneral categories . Floor-mounted cantilever
systemstable/gantry systems
10. High pressure water starts at the pump , and isWORKING PROCESS delivered
through special high pressure Atplumbing to the nozzle . the nozzle , abrasive is
introduced & as the abrasive/water mixture exits , cutting is Once the jet has exited the
nozzle ,performed . the energy is dissipated into the catch tank , which is usually full of
water & debris from previous cut .
FIG . SCHEMATIC DIAGRAM OF AJM11.
12. Obtainable tolerances There are main features of AJM AJM FEATURES
Stability of Accuracy of table Material thicknessMaterial to machine Control
abrasive jettable
Around MACHINE ASPECTS13. Speed Nozzle focus Acceleration Feed
rate Inside cornercurves Hardness Pump pressurecutting & Software
controllingthickness Power at the nozzlethe motion
TYPES OF ABRASIVE14. Different types of abrasive are used in
abrasiveMATERIALS jet machining like garnet , aluminum oxide , olivine , silica sand
, Virtually any material can be cut by usingsilicon carbide ,etc . abrasive jet machining
method , i.e harder materials like titanium to Abrasive particles must be hard ,high
toughness,steel. irregular in shape & edges should be sharp .
Extremely ADVANTAGES15. fast setup & There is only one No start hole
requiredprogramming No heat generated in work Less vibration Low capital
costtool Environmentally friendlypiece
Low metal DISADVANTAGES16. Abrasive powder Due to stay cutting accuracy
is affectedremoval rate Tapper is also a problemcannot be reused
CONCLUSION17. The better performance , and the applications represented above
statements confirm that ABRASIVE JET MACHINING is continue to expand The new
softwares used to minimize time and. investments , there by making it possible for
more manufacturers of precision parts to install AJM centers .
Ads by safesaver. More Info | Hide These Ads
Follow us on LinkedIn
Follow us on Twitter
Find us on Facebook
Find us on Google+
Learn About Us
About
Careers
Our Blog
Press
Contact Us
Help & Support
Using SlideShare
SlideShare 101
Terms of Use
Privacy Policy
Copyright & DMCA
Community Guidelines
SlideShare on Mobile
Pro & more
Go PRO
Enterprise Sales
PRO Features
Developers & API
Developers Section
Developers Group
Engineering Blog
Blog Widgets
LinkedIn Corporation 2014
RSS Feed
ENGLISH



Explore


Upload
Go Pro
Login
Signup
Ads by safesaver. More Info | Hide These Ads
Email
Like
Save
Embed




















1
/18
Share
Ads by safesaver. More Info | Hide These Ads
Related
Abrasive water jet machining 93 views Like
Fy3310631066 129 views Like
phonetics 72 views Like
Nanofinishing 1877 views Like
Theoretical and graphical analysis of abrasivewater jetturning
74 views Like
Final evaluating materialremoval 61 views Like
N A ROBSON BROCHURE 727 views Like
KMT Waterjet Systems Stone Cutting Presentation 5834 views Like
KMT Waterjet Systems Metal Cutting Presentation 7894 views Like
Waterjet cutting milling 127 views Like
Blasting Cabinet byKrishna engineers 127 views Like
WATER JET CUTTING 1929 views Like
37624 _advanced_machining_processes.mcgraw-
hill_._2005.isbn0071453342_ 6500 views Like
Ef25803806 190 views Like
Final tech forum abrasives 181 views Like
Cl34527530 434 views Like
8 cuft classic-blast-machine 427 views Like
SandBlasting Products 184 views Like
Asm metals handbook volume 5 surface engineering 1003 views Like
N55 massarsky rev 268 views Like
Effect of Temperature on Wear Rate of Si-Epoxy- Eglass Polymer
composite Materia 60 views Like
Afp sme-turbo-finish 378 views Like
Analysis of abrasive jet machining parameters on mrr and kerf width
of hard and 689 views Like
Effect of the process parameters on the surface roughness during
magnetic 220 views Like
15ap2 176 views Like
Dental Materials: Properties & Manipulation, 10/e 1771 views Like
Mesin sandblasting clemco 623 views Like
Water jet cutting technology 2501 views Like
Flow wintech presentation 350 views Like
October 2013 f2 deburring 1 205 views Like
Flow Water Jet Cutting Machine Supplier, Manufacturer, Ahmedabad
117 views Like
Micromachining using an abrasive jet 855 views Like
Investigations on Wear by Slurry Abrasion of Hardfaced Low Alloy
Steel 310 views Like
Water jet manual 229 views Like
Follow
Presentation of-abrasive-jet-machining
by Amol Ranvare, Working at Student on J an 07, 2012
8,484 views
DFDFF
1 comment
11 of 1 comment
Manish Chander TANX.. ya its very helpful ... :) 1 year ago

Subscribe to comments Post Comment
2 Likes
pranavas 11 months ago
shivashree 11 months ago
Presentation of-abrasive-jet-machining
Presentation Transcript
WHAT IS1. It is the material removal process where theABRASIVE JET
MACHINING ? material is removed by high velocity stream of air/gas or water and An
abrasive is small, hard particle having sharpabrasive mixture . High velocity jet is
aimed at a surfaceedges and an irregular shape . under controller condition .
Motion system Mixing tube Nozzle Pump Control system Abrasivedelivery
system COMPONENTS OF ABRASIVE JETMACHINING2.
3. 1. ABRASIVE DELIVERY SYSTEMAuto 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 .
The4. 2.CONTROL SYSTEM control algorithm that computes exactly how the feed
rate should vary for a given geometry in a given material to make a precise Thepart .
algorithm actually determines desired variation in the feed rate & the tool path to provide
an extremely smooth feed rate .
5. Crankshaft3.PUMP & intensifier pump are mainly use in the The intensifier pump
was the only pump capableabrasive jet machine . Crankshaft pumps are moreof
reliably creating pressures high . efficient than intensifier pumps because they do not
require a power robbing hydraulic system ultra high pressure & more stroke per minute .
All abrasive jet systems use the same6. 4.NOZZLE basic two stage nozzle . First ,
water passes through a small diameter jewel orifice to form a narrow The abrasive
particles arejet . accelerated by the moving stream of water & they pass into a long
hollow cylindrical Generally two type of nozzleceramic mixing tube. use , right angle
head & straight head .
FIG. OF NOZZLE7.
8. The mixing tube is where the abrasive mixes5. MIXING TUBE with the The
mixing tube should be replaced whenhigh pressure water . For maximum accuracy
,tolerances drop below acceptable levels . replace the mixing tube more frequently .
9. 6.MOTION SYSTEM In order to make precision parts , an abrasive jet system must
have a precision x-y table and Tables fall into threemotion control system . Integrated
Floor-mounted gantry systemsgeneral categories . Floor-mounted cantilever
systemstable/gantry systems
10. High pressure water starts at the pump , and isWORKING PROCESS delivered
through special high pressure Atplumbing to the nozzle . the nozzle , abrasive is
introduced & as the abrasive/water mixture exits , cutting is Once the jet has exited the
nozzle ,performed . the energy is dissipated into the catch tank , which is usually full of
water & debris from previous cut .
FIG . SCHEMATIC DIAGRAM OF AJM11.
12. Obtainable tolerances There are main features of AJM AJM FEATURES
Stability of Accuracy of table Material thicknessMaterial to machine Control
abrasive jettable
Around MACHINE ASPECTS13. Speed Nozzle focus Acceleration Feed
rate Inside cornercurves Hardness Pump pressurecutting & Software
controllingthickness Power at the nozzlethe motion
TYPES OF ABRASIVE14. Different types of abrasive are used in
abrasiveMATERIALS jet machining like garnet , aluminum oxide , olivine , silica sand
, Virtuallsilicon carbide ,etc .y any material can be cut by using abrasive jet machining
method , i.e harder materials like titanium to Abrasive particles must be hard ,high
toughness,steel. irregular in shape & edges should be sharp .
Extremely ADVANTAGES15. fast setup & There is only one No start hole
requiredprogramming No heat generated in work Less vibration Low capital
costtool Environmentally friendlypiece
Low metal DISADVANTAGES16. Abrasive powder Due to stay cutting accuracy
is affectedremoval rate Tapper is also a problemcannot be reused
CONCLUSION17. The better performance , and the applications represented above
statements confirm that ABRASIVE JET MACHINING is continue to expand The new
softwares used to minimize time and. investments , there by making it possible for
more manufacturers of precision parts to install AJM centers .
Ads by safesaver. More Info | Hide These Ads
Follow us on LinkedIn
Follow us on Twitter
Find us on Facebook
Find us on Google+
Learn About Us
About
Careers
Our Blog
Press
Contact Us
Help & Support
Using SlideShare
SlideShare 101
Terms of Use
Privacy Policy
Copyright & DMCA
Community Guidelines
SlideShare on Mobile
Pro & more
Go PRO
Enterprise Sales
PRO Features
Developers & API
Developers Section
Developers Group
Engineering Blog
Blog Widgets
LinkedIn Corporation 2014
RSS Feed
ENGLISH


Search


Forums
Latest Topics
Categories
Submit your Article
About
Contact us
FAQ
Home Manufacturing Technology Unconventional Machining Processes Abrasive Jet Machining
(AJM)
Abrasive Jet Machining (AJM)
Unconventional Machining Processes Add comments
Jan 182013

Abrasive Jet Machining (AJM), also known as micro-abrasive blasting, is a mechanical energy
based unconventional machining process used to remove unwanted material from a given
workpiece.
The process makes use of an abrasive jet with high velocity, to remove material and provide
smooth surface finish to hard metallic workpieces. It is similar to Water Jet Machining (WJM).
This article explains the construction and working of AJM listing its advantages, disadvantages
and applications. The contents of this article are listed below:
1. Schematic Diagram
2. Construction
3. Working
4. Operations performed using AJM (Applications of AJM)
5. Advantages
6. Disadvantages
Schematic Diagram of Abrasive Jet Machining:
A simple schematic diagram of Abrasive Jet Machining (AJM) is shown below:

Construction of Abrasive Jet Machining (AJM):
The constructional requirements of Abrasive Jet Machining (AJM) are listed and described
below:
1. Abrasive jet: It is a mixture of a gas (or air) and abrasive particles. Gas used is carbon-di-oxide or
nitrogen or compressed air. The selection of abrasive particles depends on the hardness and
Metal Removal Rate (MRR) of the workpiece. Most commonly, aluminium oxide or silicon
carbide particles are used.
2. Mixing chamber: It is used to mix the gas and abrasive particles.
3. Filter: It filters the gas before entering the compressor and mixing chamber.
4. Compressor: It pressurizes the gas.
5. Hopper: Hopper is used for feeding the abrasive powder.
6. Pressure gauges and flow regulators: They are used to control the pressure and regulate the
flow rate of abrasive jet.
7. Vibrator: It is provided below the mixing chamber. It controls the abrasive powder feed rate in
the mixing chamber.
8. Nozzle: It forces the abrasive jet over the workpiece. Nozzle is made of hard and resistant
material like tungsten carbide.
Working:
Dry air or gas is filtered and compressed by passing it through the filter and compressor.
A pressure gauge and a flow regulator are used to control the pressure and regulate the flow rate
of the compressed air.
Compressed air is then passed into the mixing chamber. In the mixing chamber, abrasive powder
is fed. A vibrator is used to control the feed of the abrasive powder. The abrasive powder and the
compressed air are thoroughly mixed in the chamber. The pressure of this mixture is regulated
and sent to nozzle.
The nozzle increases the velocity of the mixture at the expense of its pressure. A fine abrasive jet
is rendered by the nozzle. This jet is used to remove unwanted material from the workpiece.
For a good understanding of construction and working of AJM, refer the schematic diagram
above.
Operations that can be performed using Abrasive Jet
Machining (AJM):
The following are some of the operations that can be performed using Abrasive Jet Machining:
1. Drilling
2. Boring
3. Surface finishing
4. Cutting
5. Cleaning
6. Deburring
7. Etching
8. Trimming
9. Milling
Advantages of Abrasive Jet Machining:
Surface of the workpiece is cleaned automatically.
Smooth surface finish can be obtained.
Equipment cost is low.
Hard materials and materials of high strength can be easily machined.
Disadvantages of Abrasive Jet Machining:
Metal removal rate is low
In certain circumstances, abrasive particles might settle over the workpiece.
Nozzle life is less. Nozzle should be maintained periodically.
Abrasive Jet Machining cannot be used to machine soft materials.
You may also Read:
Classification of Unconventional Machining Processes based on Energy Used
Unconventional Machining Processes Introduction and Classification
Water Jet Machining (WJM)
Process Parameters of Abrasive Jet Machining
Bookmark, Email or Share this Page
Share on favorites Share on email Share on facebook Share on twitter Share on print Share on gmail
Share on stumbleupon Share on tumblr Share on pinterest_share Share on google More Sharing Services
17
Get Fresh Content from Mechteacher.com!
Enter email address


Written by Surjeet S
I am a mechanical engineering student, an engineering designer and an article writer. I am the
editor-in-chief of mechteacher.com.
Fluid Flow Process Parameters of Abrasive Jet Machining
Get Fresh Content from Mechteacher.com!
Enter email addre


Latest Articles
How to assemble a universal joint [Tutorial]
Parts of a Universal Joint
Universal Joint An Introduction
Knuckle Joint Introduction, Parts and Applications
Spur Gear Advantages, Disadvantages & Applications
Recent Comments
Surjeet S on Kinematic Pair Definition and Types
Ashley Lionell on Kinematic Pair Definition and Types
hardik on Reheat Rankine Cycle Processes with h-s Diagram
reygie palma on Beam Definition and Types
reygie palma on Beam Definition and Types

2013 Mechteacher.com

Terms of Service | Sitemap | Copyright

Read more: http://mechteacher.com/abrasive-jet-machining/#ixzz2sEFDtAnI