ABRASIVE JET MACHINING (AJM)

1. Fine particles (0.025mm) are accelerated in a gas stream (commonly air at a few times atmospheric pressure). 2. The particles are directed towards the focus of machining (less than 1mm from the tip). 3. As the particles impact the surface, they fracture off other particles.

Figure 9.46 Schematic illustration of the abrasive-jet machining process.

As the particle impacts the surface, it causes a small fracture, and the gas stream carries both the abrasive particles and the fractured (wear) particles away. Brittle and fragile work pieces work better. Material Removal Rate

Factors that effect the process are, - mrr - geometry of cut - roughness of surface produced - the rate of nozzle wear The factors are in turn effected by, - the abrasive: composition; strength; size; mass flow rate - the gas composition, pressure and velocity - the nozzle: geometry; material; distance to work; inclination to work The abrasive, - materials: aluminum oxide (preferred); silicon carbide - the grains should have sharp edges - material diameters of 10-50 micro m 15-20 is optimal - should not be reused as the sharp edges are worn down and smaller particles can clog nozzle.

Summary of AJM characteristics - Mechanics of material removal - brittle fracture by impinging abrasive grains at high speed - media - Air, CO2 - abrasives: Al2O3, SiC, 0.025mm diameter, 2-20g/min, non-recirculating - velocity = 150-300 m/sec - pressure = 2 to 10 atm. - nozzle - WC, sapphire, orifice area 0.05-0.2 mm2, life 12-300 hr., nozzle tip distance 0.25-75 mm - critical parameters - abrasive flow rate and velocity, nozzle tip distance from work surface, abrasive grain size and jet inclination - materials application - hard and brittle metals, alloys, and nonmetallic materials (e.g., germanium, silicon, glass, ceramics, and mica) Specially suitable for thin sections - shape (job) application - drilling, cutting, deburring, etching, cleaning - limitations - low metal removal rate (40 mg/min, 15 mm3/min), embedding of abrasive in workpiece, tapering of drilled holes, possibility of stray abrasive action.

DEFINITION OF ABRASIVE WATER JET

An abrasive water jet is a jet of water which contains abrasive material. Usually the water exits a nozzle at a high speed and the abrasive material is injected into the jet stream. This process is sometimes known as entrainment in that the abrasive particles become part of the moving water much as passengers become part of a moving train. Hence as with a train the water jet becomes the moving mechanism for the particles. However a high speed jet of a premixture of the abrasive and the water would also be defined as an abrasive water jet. The purpose of the abrasive water jet is to perform some machining or finishing operation such as cutting, boring, turning, etc.

Applications Abrasive water jet cutting is highly used in aerospace, automotive and electronics industries. In aerospace industries, parts such as titanium bodies for military aircrafts, engine components (aluminium, titanium, heat resistant alloys), aluminium body parts and interior cabin parts are made using abrasive water jet cutting. In automotive industries, parts like interior trim (head liners, trunk liners, door panels) and fibre glass body components and bumpers are made by this process. Similarly, in electronics industries, circuit boards and cable stripping are made by abrasive water jet cutting.

Advantages of abrasive water jet cutting In most of the cases, no secondary finishing required No cutter induced distortion Low cutting forces on workpieces Limited tooling requirements Little to no cutting burr Typical finish 125-250 microns Smaller kerf size reduces material wastages No heat affected zone Localises structural changes No cutter induced metal contamination Eliminates thermal distortion No slag or cutting dross

Limitations of abrasive water jet cutting Cannot drill flat bottom Cannot cut materials that degrades quickly with moisture Surface finish degrades at higher cut speeds which are frequently used for rough cutting. The major disadvantages of abrasive water jet cutting are high capital cost and high noise levels during operation.

USES OF ABRASIVE WATER JET MACHINING :

Abrasive water jet machining if appropriate and cost effect for a number of procedures and materials. Several of these are listed below: cutting of difficult-to-machine materials by abrasive water jets milling and 3-D-shaping by abrasive water jets; turning by abrasive water jets; piercing and drilling by abrasive water jets; polishing by abrasive water jets; These operations are similar to just plain water jet machining but because of special considerations such as the type of material or shape complexity require the addition of the abrasive phase. Operations where plain water jet machining would be sufficient include: cutting of materials such as plastics, thin metal, textiles, or foam deburring surface peening conventional machining with water jet assist.