Académique Documents
Professionnel Documents
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By
KRUSHNA PRASAD PRADHAN Roll 10503048
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
NATIONALINSTITUTEOFTECHNOLOGY ROURKELA,769008
ACKNOWLEDGEMENT
IdeemitaprivilegetohavebeenastudentofMechanicalEngineeringstreeminNational InstituteofTechnology,Rourkela.Itakethisopportunitytoexpressmygratitudetoallthose who motivated, encouraged and helped me in the project work. Im grateful to my supervisor,Prof.C.K.Biswas,forhiskindsupport,guidanceandencouragementthroughout theprojectwork,alsoforintroducingtomethistopic,whichhasbeenveryinterestingand hasgivenusgreatinsighttothefutureworkonthisarea.Wewouldliketotakethechance toexpressourappreciationtoourfamilymembers.Theircontinuousloveandsupportgave usthestrengthforpursuingourdream.Specialthankstoourfriendsandothermembersof thedepartmentforbeingsosupportiveandhelpfulineverypossibleway. NITRourkela May11,2009 KrushnaPrasadPradhan RollNo10503048
DepartmentofMechanicalEngineering NationalInstituteofTechnology,Rourkela
CONTENTS
TITLE PARTONE 1. Introduction 2. Equipment 3. VariablesinAbrasiveJetMachine 4. CharacteristicsofdifferentVariables 5. Advantages 6. Disadvantages 7. Application: PARTTWO 1. Literaturesurvey: PARTTHREE 1. DESIGNOFCOMPONENTS 1. XYTable: 2. BallScrew: 3. LMGuideorLinearMotionGuideWay: 4. SupportUnit: 5. NutBracket: PAGENO. 4 5 5 7 7 8 8 9 10 11 17 18 18 22 25 30 31
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32 33 34 35 37 38 42 42 43 44 45 46 47 48 49 49 50 51 52
ii. Vibratingunit a. Abrasivecontainer b. Cam 5. CostEstimation PARTFOUR 1. Nozzle 2. Cam 3. Abrasivecontainer 4. Vibratingassembly CONCLUSION
BIBLIOGRAPHY&REFERENCES
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ABSTRACT
AbrasiveJetMachining(AJM)istheprocessofmaterialremovalfromaworkpiecebythe applicationofahighspeedstreamofabrasiveparticlescarriedinagasmediumfroma nozzle.Thematerialremovalprocessismainlybyerosion.TheAJMwillchieflybeusedto cutshapesinhardandbrittlematerialslikeglass,ceramicsetc.themachinewillbe automatedtohave3axestravel.ThedifferentcomponentsofAJMareHorizontalmotion module(XYTable),Verticalmotionmodule(Zmotion),Vibrator,dehumidifier,Pressure Regulator,andDustfilteretc.Thedifferentcomponentsareselectedafterappropriate designcalculations. Inthisproject,amodeloftheAbrasiveJetMachineisdesignedusingCADpackageslike AutoCAD,CATIAetctakingintoconsiderationofcommerciallyavailablecomponents.Care hasbeentakentouselessfabricatedcomponentsratherthandirectlyprocuringthem, because,thelackofaccuracyinfabricatedcomponentswouldleadtoadiminished performanceofthemachine.
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Part
One
INTRODUCTION
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1.1Introduction
AbrasiveJetMachining(AJM)istheremovalofmaterialfromaworkpiecebytheapplication ofahighspeedstreamofabrasiveparticlescarriedingasmediumfromanozzle.TheAJM processdiffersfromconventionalsandblastinginthattheabrasiveismuchfinerandthe processparametersandcuttingactionarecarefullycontrolled. Theprocessisusedchieflytocutintricateshapesinhardandbrittlematerialswhichare sensitivetoheatandhaveatendencytochipeasily.Theprocessisalsousedfordeburring andcleaningoperations.AJMisinherentlyfreefromchatterandvibrationproblems.The cuttingactioniscoolbecausethecarriergasservesasacoolant.
1.2Equipment
AschematiclayoutofAJMisshowninFig1.Thefilteredgas,suppliedunderpressuretothe mixingchambercontainingtheabrasivepowderandvibratingat50c/s,entrainsthe abrasiveparticleandisthepassedintoaconnectinghose.Thisabrasiveandgasmixture emergesfromasmallnozzleathighvelocity.Theabrasivepowderfeedrateiscontrolledby theamplitudeofvibrationofthemixingchamber.Apressureregulatorcontrolsthegasflow andpressure. Thenozzleismountedonafixture.Eithertheworkpieceorthenozzleismovedbycams pantographorothersuitablemechanismstocontrolthesizeandshapeofthecut.Hand operationissometimesadequatetoremovesurfacecontaminationsorincuttingwhere accuracyisnotverycritical.Dustremovalequipmentisnecessarytoprotectthe environment.Commercialbenchmountedunitsincludingallcontrols,motionproducing devices,anddustcontrolequipmentareavailable.
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FIG1:SCHEMATICLAYOUTOFABRASIVEJETMACHINE Themajorcomponentsare: 1. Aircompressor. 2. Airfilter. 3. Dehumidifier. 4. PressureGauge. 5. PressureRegulator. 6. VibratororMixer. 7. Nozzle. 8. HorizontalandVerticalmotionmodule(forxyzmotion). 9. Arrangementtoholdtheworkpiece.
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1.3VariablesinAbrasiveJetMachine:
Thevariablesthatinfluencetherateofmetalremovalandaccuracyofmachininginthis processis: 1. Carriergas 2. Typesofabrasive 3. Sizeofabrasivegrain 4. Velocityofabrasivejet 5. Flowrateofabrasive 6. Workmaterial 7. Geometry,compositionandmaterialofnozzle 8. Nozzleworkdistance(standoffdistance)
9. Shapeofcutandoperationtype
1.3.1CharacteristicsofdifferentVariables:
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Standoffdistance Workmaterial
partapplication
Drilling,cutting,deburring,cleaning
TABLE1
1.4Advantages:
1. Abilitytocutintricateholesshapeinmaterialsofanyhardnessandbrittleness. 2. Abilitytocutfragileandheatsensitivematerialwithoutdamage. 3. Nochangeinmicrostructureasnoheatisgeneratedintheprocess. 4. Lowcapitalcost.
1.5Disadvantages:
1. Materialremovalrateislowandhenceitsapplicationislimited. 2. Straystringscanoccurandhenceitsapplicationislimited. 3. Embeddingoftheabrasiveintheworkpiecesurfacemayoccurwhilemachiningsofter material. 4. Theabrasivematerialmayaccumulateatnozzleandfailtheprocessifmoistureispresentin theair. 5. Itcannotbeusedtodrillblindholes.
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1.6Application:
ThemajorfieldofapplicationofAJMprocessisinthemachiningofessentiallybrittlematerialsand heatsensitivematerialslikeglass,quartz,sapphire,semiconductormaterials,micaandceramics.Itis alsousedincuttingslot,thinsections,countering,drilling,deburring,forproducingintegrateshapes inhardandbrittlematerials.ItisoftenusedforcleaningandpolishingofplasticsnylonandTeflon components.Delicatecleaning,suchasremovalofsmudgesfromantiquedocuments,isalso possiblewithAJM. 9|P a g e
PART TWO
LITERATURE SURVEY
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2.1Literaturesurvey:
TheliteraturestudyofAbrasiveJetMachinerevealsthattheMachiningprocesswas startedafewdecadesago.Tilldatetherehasbeenathroughanddetailedexperimentand theoreticalstudyontheprocess.Mostofthestudiesargueoverthehydrodynamic characteristicsofabrasivejets,henceascertainingtheinfluenceofalloperationalvariables ontheprocesseffectivenessincludingabrasivetype,sizeandconcentration,impactspeed andangleofimpingement.Otherpapersfoundnewproblemsconcerningcarriergas typologies,nozzleshape,sizeandwear,jetvelocityandpressure,standoffdistance(SOD), ornozzletipdistance(NTD).Thesepapersexpresstheoverallprocessperformanceinterms ofmaterialremovalrate,geometricaltolerancesandsurfacefinishingofworkpieces,as wellasintermsofnozzlewearrate.Finally,thereareseveralsignificantandimportant paperswhichfocusoneitherleadingprocessmechanismsinmachiningofbothductileand brittlematerials,oronthedevelopmentofsystematicexperimentalstatisticalapproaches andartificialneuralnetworkstopredicttherelationshipbetweenthesettingsof operationalvariablesandthemachiningrateandaccuracyinsurfacefinishing.
(Ref17)
Computationalfluiddynamics(CFD)simulationoftheformationanddischarge
(Ref20)
Experimentshavebeenperformedoneffectofjetpressure,abrasiveflowrate
andworkfeedrateonsmoothnessofthesurfaceproducedbyabrasivewaterjetmachining ofcarbideofgradeP25.CarbideofgradeP25isveryhardandcannotbemachinedby conventionaltechniques.Theabrasiveusedininvestigationswasgarnetofmeshsize80.It wastriedtocutcarbidewithlowandmediumlevelofabrasiveflowrate,butthejetfailed tocutcarbidesinceitistoohardandveryhighlevelofenergyisrequired.Minimumrateof abrasiveflowthatmadeitpossibletocutcarbideefficientlywas135gmin1.Withincrease injetpressurethesurfacebecomessmootherduetohigherkineticenergyoftheabrasives. Butthesurfacenearthejetentranceissmootherandthesurfacegraduallybecomes rougherdownwardsandistheroughestnearthejetexit.Increaseinabrasiveflowratealso makesthesurfacesmootherwhichisduetotheavailabilityofhighernumberofcutting edgesperunitareaperunittime.Feedratedidntshowsignificantinfluenceonthe machinedsurface,butitwasfoundthatthesurfaceroughnessincreasesdrasticallynearthe jetentrance. Thestudyoftheresultsofmachiningundervariousconditionsapprovesthata commercialAJMmachinewasused,withnozzlesofdiameterrangingfrom0.45to0.65mm, thenozzlematerialsbeingeithertungstencarbideorsapphire,bothofwhichhavehightool lives.Siliconcarbideandaluminumoxidewerethetwoabrasivesused.Otherparameters studiedwerenozzletipdistances(510mm),sprayangles(60and90)andpressures(5 and7bars)formaterialslikeglass,ceramics,andelectrodischargemachined(EDM)die steel.TheholesdrilledbyAJMmaynotbecircularandcylindricalbutalmostellipticaland
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bellmouthed.Highmaterialremovalrateconditionsdonotnecessarilyyieldsmallnarrow cleancutmachinedareas.
(Ref16)
StudiesrevealthatAJMisanattractivemicromachiningmethodforceramic
AbrasiveWaterJet(AWJ)turningisatechnologythatstilltriestofinditsniche
Themachiningprocessproducesnoheatandhencechangesinmicrostructureor strengthofthesurfaceisunlikely.TheairactsasacoolantandhenceAJMprocesshasa
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Inrecentyearsabrasivejetmachininghasbeengainingincreasingacceptabilityfor deburringapplications.Theinfluenceofabrasivejetdeburringprocessparametersisnot knownclearly.AJMdeburringhastheadvantageovermanualdeburringmethodthat generatesedgeradiusautomatically.Thisincreasesthequalityofthedeburred components.Theprocessofremovalofburrandthegenerationofaconvexedgewere foundtovaryasafunctionoftheparametersjetheightandimpingementangle,withafixed SOD.Theinfluenceofotherparameters,viz.nozzlepressure,mixingratioandabrasivesize areinsignificant.TheSODwasfoundtobethemostinfluentialfactoronthesizeofthe radiusgeneratedattheedges.Thesizeoftheedgeradiusgeneratedwasfoundtobe limitedtotheburrrootthickness.
(Ref15)
Abrasivejetfinishingcombinedwithgrindinggivesrisetoaprecisionfinishing
Abrasivewaterjetmachinesarebecomingmorewidelyusedinmechanical machining.Thesemachinesoffergreatadvantagesinmachiningcomplexgeometricalparts
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Qualityofthesurfaceproducedduringabrasivewaterjetmachiningof
aluminumhasbeeninvestigatedinrecentyears.Thetypeofabrasiveusedwasgarnetof meshsize80.Thecuttingvariableswerestandoffdistanceofthenozzlefromthework surface,workfeedrateandjetpressure.Theevaluatingcriteriaofthesurfaceproduced werewidthofcut,taperofthecutslotandworksurfaceroughness.Itwasfoundthatin ordertominimizethewidthofcut;thenozzleshouldbeplacedclosetotheworksurface. Increaseinjetpressureresultsinwideningofthecutslotbothatthetopandatexitofthe jetfromthework.However,thewidthofcutatthebottom(exit)wasalwaysfoundtobe largerthanthatatthetop(atastandoffdistanceof3mmandtheworkfeedrateof15mm min1).Itwasfoundthatthetaperofcutgraduallyreduceswithincreaseinstandoff distanceandwasclosetozeroatthestandoffdistanceof4mm(atajetpressureof30ksi andaworkfeedrateof15mmmin1).Thefeedrateoftheworkshouldbekeptwithin40 mmmin1(atthejetpressureof30ksiandthestandoffdistanceof3mm),becauseafeed ratebeyond40mmmin1resultsinsharpincreaseintaperangle.Thejetpressuredoesnot
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showsignificantinfluenceonthetaperanglewithintherangeofworkfeedandthestand offdistanceconsidered.Bothstandoffdistanceandtheworkfeedrateshowstrong influenceontheroughnessofthemachinedsurface.Hencestandoffdistanceshouldbe keptwithin3mm(atajetpressureof30ksiandaworkfeedrateof15mmmin1)andthe workfeedrateshouldbekeptwithin30mmmin1(atajetpressureof30ksiandastand offdistanceof3mm)inordertohaveagoodsurfacefinish,sincebeyondthosevaluesof theparameterstheroughnessofthemachinedsurfacerisessharply.Increaseinjetpressure showspositiveeffectintermsofsmoothnessofthemachinedsurface.Withincreaseinjet pressure,thesurfaceroughnessdecreases(atastandoffdistanceof3mmandworkfeedof 15mmmin1).Thisisduetofragmentationoftheabrasiveparticlesintosmallersizesata higherpressureandduetothefactthatsmallerparticlesproducesmoothersurface.So withinthejetpressureconsidered,theworksurfaceissmoothernearthetopsurfaceand graduallyitbecomesrougherathigherdepths.
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Part
Three
DESIGNOFCOMPONENTS
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3.1DESIGNOFCOMPONENTS 3.1.1XYTable:
XYtableisthemostimportantpartoftheAJMoverwhichtheworkpiecehastobekeptand machined.ThetravelofXYtablehasbeendecidedtobe400x350mm. ThedifferentcomponentsoftheXYtableare: 1. LMguideway(2pairs4nos.) 2. Ballscrew(2nos.) 3. Supportunit(2fixed&2supported) 4. Nutbracket(2nos.) 5. Couplings(2nos.) 6. Standardnutsandbolts. 7. Othercomponents(tobemanufacturedinthelab). TheXYtableconsistsoftwoparts:(a)Uppertable,(b)Lowertable.Theuppertableisresponsible forxmovementandhasatravelof400mm.Thelowertablehasatravelof350mmandis responsiblefortheymotionoftheworkpiece. Thedifferentdiagramsoftheassembledviewsalongwithdimensionshavebeenshownbelow.
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FIG2:XYTABLEASSEMBLY(ISOMETRICVIEW)
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FIG3:XYTABLEASSEMBLY(2DVIEWS)
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FIG4:XYTABLE(TOPVIEW)
FIG5:XYTABLE(SIDEVIEW) 21|P a g e
3.1.2BallScrew:
Ballscrewissimilartoleadscrewsuperficiallybutthefrictionisgreatlyreducedincaseofball screwsbyinsertingrecirculatingballsinbetweenthescrewthreadandthenut.Thethreadprofileis madecircularandthenutthreadhasgotareverseshapewhichformsaspiralcavityinsidewhichthe ballsmovewhenthenutisrotated.Oncetheballsreachtheendofthenuttheyareagain recirculatedbymeansofareturnpipe.Ballscrewscanpreloadedornonpreloaded.Theaccuracy increasesincaseofpreloadedtypeofballscrewastwosetsofballsarepressedtowardeachother therebymakingtheradialclearanceclosetozero.
FIG6:RECIRCULATINGBALLSCREW
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(Travel) = 700mm.
(Uppertablebreadth)
(Allowanceforbellowscover)
(Upperarrangement)
(Bellowscoverallowance)
CommercialBallscrewsareavailablefromcompanieslike(1)THK,(2)GrampusImpexLtd.,(3) PrecisionBearingHouse,and(4)ABBAetc. Thespecificationsbycompaniesthatsatisfyourrequirementare: BNF20055RRG2850L700C7 BNF 20 05 RR G2 modelno. screwshaftdiameter lead labyrinthsealattached axialclearancegrade overallshaftlength(inmm) screwlength accuracysymbol 23|P a g e (byTHKCompany)
850L 700 C7
SFI2005C7800650P0 SFI 20 05 C7 800 650 P0 modelno.(Singlenut) screwshaftdiameter lead accuracygrade totallength screwlength precisionlevel
FIG7:SCREWTHREAD
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FIG8:BALLSCREWASSEMBLY(SHOWINGDIMESIONSANDMACHINEDENDS)
3.1.3LMGuideorLinearMotionGuideWay:
LMGuideasthenamesuggestsisusedforhighlypreciselinearmotion.Itcansustainhighloadsin anydirectionandhencecanbemountedinanydirection.Theassemblycontainsarailwhichguides ablockonit.Insidetheblock,ballorrollerarepresentwhichdrasticallyreducesthefrictionallosses. SoLMGuideispreferredinbothindustriesandroboticstoachievespecificfunctions.
FIG9:LMGUIDEASSEMBLY
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StructureandFeatures:
BallsrollinfourrowsofracewaysprecisiongroundonanLMrailandanLMblock,andendplates incorporatedintheLMblockallowtheballstocirculate.Sinceretainerplatesholdtheballs,theydo notfalloffeveniftheLMrailispulledout(exceptmodelsHSR8,10and12).Eachrowofballsis placedatacontactangleof45sothattheratedloadsappliedtotheLMblockareuniforminthe fourdirections(radial,reverseradialandlateraldirections),enablingtheLMGuidetobeusedinall orientations.Inaddition,theLMblockcanreceiveawellbalancedpreload,increasingtherigidityin the four directions while maintaining a constant, low friction coefficient. With the low sectional heightandthehighrigiditydesignoftheLMblock,thismodelachieveshighlyaccurateandstable linearmotion. 4wayequalload
FIG10:LOADONLMBLOCK Eachrowofballsisplacedatacontactangleof45sothattheratedloadsappliedtotheLMblock are uniform in the four directions (radial, reverseradial and lateral directions), enabling the LM Guidetobeusedinallorientationsandinextensiveapplications Highrigiditytype Sinceballsarearrangedinfourrowsinawellbalancedmanner,alargepreloadcanbeappliedand therigidityinfourdirectionscaneasilybeincreased
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Highdurability Even under a preload or biased load, differential slip of balls does not occur. As a result, smooth motion,highwearresistance,andlongtermmaintenanceofaccuracyareachieved.
RatedLoadsinAllDirections
ModelHSRiscapableofreceivingloadsinallfourdirections:radial,reverseradialandlateral directions.Thebasicloadratingsareuniforminthefourdirections(radial,reverseradialandlateral directions),andtheiractualvaluesareprovidedinthedimensionaltableforHSR.
EquivalentLoad
When the LM block of model HSR receives loads in the reverseradial and lateral directions simultaneously,theequivalentloadisobtainedfromtheequationbelow
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PL Reverseradialload PT Lateralload
(N) (N)
AdvantageofLMGuide 1. Smoothmovementwithnoclearance. 2. Highrunningprecisionwithease. 3. Highrigidityinalldirection. 4. Highpermissibleloadrating. 5. Highlongtermprecision. 6. Highspeedoperation. Thesecombinetogiverise 1. Lowtotalcost. 2. HighprecisioninmachinesincorporatingtheLMguide. 3. Highproductivityinthesame. 4. Substantialenergysaving. 5. Highefficiencyinmachinedesign. 6. Simplemaintenance.
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LMGuidesarecommerciallyavailablefromcompanieslike(1)THK,(2)GrampusImpexLtd.,(3) PrecisionBearingHouse,and(4)ABBAetc. Thespecificationbycompaniesthatsatisfyourrequirementis: HSR30R2SSC5700LHII HSR 30R 2 SS C5 modelno. sizespecification 2blocksperrail endseal+sideseal radialclearance standardlength accuracygrade 2rails
700L H II
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FIG11:DIMENSIONSOFLMGUIDE
3.1.4SupportUnit:
FIG13:SUPPORTUNIT(DESIGNEF)
3.1.5NutBracket:
Nutbracketisusedtobolttheballscrewnutwiththeworkloadplatform.Followingdiagramshows anutbracketalongwithaballscrewnut.
FIG14:NUTBTACKET
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3.2ZAxisAssemblyorVerticalMotionModule:
Verticalmotionmoduleisrequiredforadjustingthenozzleheightorstandoffdistancefromthe workpiece.Whendifferentoperationsaretobecarriedout,thesetuptimebetweenoperationscan beeliminatedifthenozzletipisraisedtoaheightmorethan5cm.Atthisdistancetheabrasivejet hasnegligibleerosioneffectontheworkpiece.HencethetotalZmotionhasbeendecidedtobe 100mm. ThedifferentcomponentsoftheVerticalmotionmoduleare: 1. LMguideway(1no.) 2. Ballscrew(1no.) 3. Supportunit(1fixed&1supported) 4. Couplings(1no.) 5. Nozzle(1no.) 6. Standardnutsandbolts. 7. Othercomponents(tobemanufacturedinthelab). Theassemblyviewisshowninthenextpage.
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Supportunit
Pipeholder
Nozzleholder
Nozzle
Supportunit
FIG15:VERTICALMOTIONMODULE
3.2.1LMguideway:
TheLMGuideselectedisofthetypeHSRYR.ThespecialfeatureofHSRYRisthatthetappedholes arepresentonthesideoftheLMBlockandhencetheycanbeattachedtotheloadcomponentfrom theside.
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FIG16:LMGuide(typeHSRYR)
3.2.2BallScrew&SupportUnit
TheballscrewselectedfortheZaxisassemblyisofthetypeBNT.ThesupportunitsareEKandFK forfixedendandsupportedendrespectively.ThesmallerspaceintheZassemblydoesntallowfor theuseofanutbracketfortheballscrewnut.SotheBNTtypeballscrewhasbeenselectedfrom THKcatalogueasithastappedholesonthenutitselfwhichcanbescrewedtotheloaddirectly.
FIG17:BALLSCREWANDSUPPORTUNIT
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3.2.3Nozzle:
Theabrasiveparticlesaredirectedintotheworksurfaceathighvelocitythroughnozzles.Therefore, thematerialofthenozzleissubjectedtogreatdegreeofabrasionwearandhencethesearemade ofhardmaterialssuchastungstencarbideorsyntheticsapphire.Tungstencarbidenozzlesareused forcircularcrosssectionsintherangeof0.120.8mmdiameter,forrectangularsectionsofsize0.08 x0.05to0.18x3.8mmandforsquaresectionsofsizeupto0.7mm.Sapphirenozzlesaremadeonly forcircularcrosssections.Thesizevariesfrom0.2to0.7mmdiameter.Nozzlesaremadewithan externaltapertominimizesecondaryeffectsduetoricochetingofabrasiveparticles.Nozzlesmade oftungstencarbidehaveanaveragelifeof12to30hourswhilenozzlesofsapphirelastforabout 300hourofoperationwhenusedwith27mabrasivepowder. Therateofmaterialremovalandthesizeofmachinedareaareinfluencedbythedistanceofthe nozzlefromtheworkpiece.Theabrasiveparticlesfromthenozzlefollowaparallelpathonlyfora shortdistanceandthenthejetflaresresultingintheoversizingofthehole.Itisobservedthatthejet streamisinitiallyacylinderforabout1.6mmandthenitflaresintoaconeof7includedangle.The materialremovalrateinitialincreaseswithincreaseinthedistanceofthenozzlefromtheworkpiece becauseoftheaccelerationofparticlesleavingnozzle.Thisincreaseismaximumuptoadistance about8mmandthenitsteadilydropsoffbecauseofincreaseinmachiningareaforthesame amountofabrasiveanddecreaseinvelocityofabrasivestreamduetodrag.
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FIG18:NOZZLE Workpiece
Standoff distance
Nozzletip
FIG19:Abrasiveactionofparticles
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3.2.4LimitationsofAbrasiveJetnozzles:
Despitetheirsimpledesign,abrasivejetnozzlescanbetroublesomeattimes.Therearemanydesigns,but theysharethesameproblems:
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3.3TOTALASSEMBLY
Theassemblydrawingoftheabrasivejetmachinecanberepresentedasfollows.Itcanbenoted thatthecomponentslikeaircompressor,vibrator,dehumidifier,bellowscoverandpipinghavenot beenshowninthedrawing
FIG20:SIDEVIEWOFWHOLEASSEMBLY
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FIG21:AJMFRONTVIEW
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FIG22:AJMTOPVIEW
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FIG23:AJMISOMETRICVIEW
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3.4OtherComponents
3.4.1FRLUnit(Dehumidifier):
TheFRLUnit(AirFilterRegulatorLubricatorunit)whichisotherwisecalledthemoistureseparatoror dehumidifierisrequiredforseparatingthemoisturefromair.Atmosphericairalwayscontainssome watervapourinit.Astheairwithhighvelocityisblownfromthenozzlethereisanabruptrisein pressurewhichconvertswatervapourintomoisture.Themoisturemakestheabrasiveparticlesto agglomerateandthisclogstheoutletoftheNozzle.Toavoidthiscloggingmoistureseparatorshould beusedbeforeabrasiveparticlesaremixedwithcompressedair.DifferentFRLUnitsareavailable commercially.
Outlet
Inlet
CirculationofAir
Chemicals forseparatingmoisture
FIG24:FRLUnit
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3.4.2TheVibratingUnit:
VibratingUnitisusedformixingtheairwiththeabrasiveparticles(Al2O3).TheAbrasive particlesarestoredinacontainerthroughwhichairisflown.Theparticlesareagitatedby meansofacamandmotorarrangement.Therotationofcamresultsinvibrationinthe abrasivecontainer.Theflowrateofabrasivematerialscanbecontrolledbymanipulating therotationalspeedofthemotor.Theabrasivecontainerwillhaveoneinletandoneoutlet forairpassageandwillbeverticallysuspendedfromahingedjoint. SotheVibratingUnitconsistsoffollowingparts 1. Motor(Inductiontype) 2. Cam 3. Abrasivecontainer
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AbrasiveContainer:
FIG25:TheAbrasiveContainer.
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Cam:
Camisfixedwithshaftoftheinductionmotor.Theprofileofthecamistakentobeacircular one.Thedistancebetweentwocentersasshowninfig26is3mm.Whenthemotorrotates;it makesthecontainertovibrate.Widthofcamis25mm.
FIG26:Cam
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3.3.5ApproximateCostEstimation:
TABLE:2(Costestimation)
SLNO. NAMEOFTHEITEM COSTPERSINGLE NO.OFITEMS PIECE 1 Recirculatingballscrew Xaxis Yaxis Zaxis 2 LinearMotionguideways Xaxis Yaxis Zaxis 3 SupportUnit Xaxisballscrew Yaxisballscrew Zaxisballscrew 4 5 6 FRLUnit Vice Angles Rs.10,000.00 Rs.7,000.00 Rs.5,000.00 Rs.17,000.00 Rs.14,000.00 Rs.6,000.00 Rs.3,000.00 Rs.2,500.00 Rs.2,500.00 Rs.2,500.00 Rs.2,000.00 Rs.1000.00 REQUIRED 1 1 1 1pair 1pair 1 2 2 2 1 Rs.2500.00 Rs.2,000.00 Rs.1000.00 Rs.16,000.00 TOTALCOST FORTHEITEM Rs.22,00.00 Rs.37,000.00
Otheraccessories TOTAL
Rs.7,500.00 Rs.88,000.00
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Part
Four
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4.1Nozzle:
A standard MS cylindrical rod was cut into required length by power hacksaw. The external diameterwasthenbroughtto16mmbyturningitinlatheandthenthetipwasmadebytapering oneendbythesamelathe.Ablindholeofapproximatedepth20mmwasmadeontheplannerface oftherodbymeansofa12mmdrillbitinadrillingmachine.Theendoftheblindholeformsashape of118degreetaperbecauseofthetooltipangle.Internalthreadingwasmadeby12mmtap.Then the tip of the nozzle was made by drilling it by a 0.74mm diameter drill bit to get approximate diameterof1mm.
FIG27:Nozzle
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4.2CAM:
Mildsteelofdiameter40mmwastakenasrawmaterialforthisoperation.Atfirstturningwasdone inalathetobringdownthediameterto35mm.Thentherequiredwidth(25mm)wascutbypower hacksawandboththecutfacesweremachinedinamillingmachine.Thenathroughholewasmade bya16mmdrillbitinadrillingmachine.Thecenteroffsetwastakentobe3mm.
4.3ABRASIVECONTAINER:
Theabrasivecontainerwasmadeoutofahollowcylinder.Twoironplateswereweldedonboth endsofthecontainer.Onthetopplatetwoholesweredrilledandironpipeswerefittedwiththese holes.Theinletironpipeislongersoastomakemoreagitationoftheabrasiveparticles.Theoutlet pipeisshorter.Boththepipesareclampedwithnylonpipeswhichcarriesairthroughthem.After removalofmoisturebytheFRLunitthecompressedairgoestoabrasivecontainerthroughinlet, mixeswithabrasiveparticleandthentheairwithabrasiveparticlesmovesthroughthenozzleto performthemachiningaction.
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4.5THEVIBRATORASSEMBLY:
Theanglesectionwasweldedwithbaseplatebyarcwelding.Arodwasweldedwithangleorienting itparallelwithbaseplate.Aninductionmotorwasplacedonthebaseplatebytightenwithnutbolt. Camwasfixedwithmotorshaft.Thenabrasivecontainerwasconnectedtotherodbymeansofthe holder.Thecontainerisfreetorotatearoundtherod.
FIG28:Thevibratorassembly
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CONCLUSION
InthisprojectacompletedesignoftheAbrasiveJetMachineisgiven.TheXYZmotion modulesaredesignedtakinginaccountofcurrentlyavailablecomponentsinthemarket. Thedesigningandassemblingofverylargenumberofcomponentswasatremendoustask andwascompletedontime.Howeverbecauseofsomepartscouldntbepurchasedthe wholeassemblywaslimitedtodrillingoperation. Theprojectcangobeyonditscurrentpositionandcapabilitiesbyemployingautomation intoit.ThiscanbedonebyusingsteppermotorsorDCservomotorsinterfacedwith standardPCIcontrollersorstandalonecontrollers.2Dprofilescanbeconvertedinto standardGcodesandMcodesandthatcanbesenttothemachinetoperformautomated machining.
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Bibliography&References
BOOKS
4. www.scopus.com 5. www.sciencedirect.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. Residualstressandtribologicalcharacteristicsofgroundsurfaceafterabrasivejet restrictedbygrindingwheel Authors:Liu,F.,Gong,Y.D.,Shan,Y.Q.,Cai,G.Q. Publication:JournalofNortheasternUniversity,Volume30,Issue3,Pages422425 March2009. 13. Simulationandanalysisofabrasivejetmachiningwithwheelrestrictioningrinding Authors:Wang,W.S.,Zhu,L.D.,Yu,T.B.,Yang,J.Y.,Tang,L. Publication:KeyEngineeringMaterials,Volume389390,Pages387391, 2009
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Date:Dec,2008 15. Modelingandsimulationformaterialremovalinabrasivejetprecisionfinishingwith wheelasrestraint. Authors:Li,C.H.,Ding,Y.C.,Lu,B.H. Publication:ProceedingsoftheIEEEInternationalConferenceonAutomationand Logistics,ICAL2008,Articlenumber4636666,Pages28692873,2008 16. Abrasivejetmicromachiningofplanarareasandtransitionalslopes Authors:Ghobeity,A.;Spelt,J.K.;Papini,M. Publication:JournalofMicromechanicsandMicroengineering,Volume18,Issue5, pp.055014. PublicationDate:01/05/2008 17. ThreeDimensionalCFDSimulationofTwoPhaseFlowInsidetheAbrasiveWaterJet CuttingHead Authors:UmbertoPrisco;MariaCarminaD'Onofrio. Publication:InternationalJournalofComputationalMethodsinEngineeringScience
andMechanics9(5),pp.300319
19. Surfaceevolutionmodelsforabrasivejetmicromachiningofholesinglassand polymethylmethacrylate(PMMA) Authors:Ghobeity,A.;Getu,H.;Papini,M.;Spelt,J.K. Publication:JournalofMicromechanicsandMicroengineering,Volume17,Issue11, pp.21752185(2007). Date:11/2007 20. SurfaceRoughnessofCarbidesProducedbyAbrasiveWaterJetMachining Authors:Khan,AhsanAli;Awang,MohdEfendeeBin;Annuar,AhmadAzwariBin Publication:JournalofAppliedScience,vol.5,Issue10,p.17571761 Date:06/2005 21. AStudyonAbrasiveWaterJetMachiningofAluminumwithGarnetAbrasives. Authors:Khan,AhsanAli;Munajat,NoraziatyBt.;Tajudin,HarnisahBt. Publication:JournalofAppliedScience,vol.5,Issue9,p.16501654 Date:01/2005 22. Effectofworkpiecepropertiesonmachinabilityinabrasivejetmachiningofceramic materials Authors:M.Wakuda,Y.YamauchiandS.Kanzaki Publication:PrecisionEngineering,Volume26,Issue2,April2002,Pages193198 23. Anexperimentalstudyontheabrasivejetdeburringofcrossdrilledholes Authors:R.Balasubramaniam,J.KrishnanandN.Ramakrishnan Publication:JournalofMaterialsProcessingTechnology,Volume91,Issues13,30
June1999,Pages178182
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