ABRASIVE JET MACHINING (AJM)

[1] PROCESS PRINCIPLE: A Focused Stream of High Velocity Abrasive Particles Laden in a Carrier Gas Coming
Out of a Nozzle Impinges on the Target Surface and Erodes it.
The Impact Causes a Tiny Brittle Fracture and Carrier Gas Carries Away the Dislodged Small Workpiece Particle
The Resulting Erosion can be Used for Cutting, Etching, Cleaning, Deburring, Polishing, Drilling
The Process is More Suitable when Work Material is Brittle and Fragile
Soft & Resilient Materials (Rubber & Plastics) Resist Chipping Action and Cannot be Processed Effectively by AJM
AJM Differs from Conventional
Sand Blasting Process in that the
Finer Abrasive Particles and
Carefully Controlled Cutting Action
and Process Parameters
No Workpiece Chatter or Vibration
Occurs Because Large Quantity
and Small Mass of the Abrasives
Result in Uniform Loading of the
Part
AJM can Produce Fine, Intricate
Details in Extremely Brittle Objects
Workpiece does Not Experience
Any Thermal Damage

[2] AJM PROCESS EQUIPMENT: Main Elements of an AJM Machine are

[1] Gas Propulsion System;
[2] Metering System;
[3] Delivery System;

[4] Abrasive Collection System

[2.1] GAS PROPULSION SYSTEM:

To Provide Steady Supply of Clean & Dry Gas Used to Propel the Abrasive Particles
Either Bottled Gas or Air Compressor May be Used.
Use of Air Compressor Requires Proper Line Filters to Avoid Water or Oil Contamination of Abrasive Powders
Commonly Used Gas: Nitrogen and Carbon Dioxide; Oxygen Must be Avoided Presents Fire Hazards.

[2.2] METERING SYSTEM:

To Inject Uniform Adjustable Flow of Abrasive Particles into the Gas Stream
Accomplished by Powder Hopper that Feeds the Abrasive Particles into a Vibrating Chamber that Causes the
Powder to be Metered Uniformly into the Jet Stream
Abrasive Powder Flow Rate is Adjusted by Varying the Vibration Amplitude

[2.3] DELIVERY SYSTEM: Consists of Three Elements namely: Nozzles, Masks, and Abrasives
[2.3.1] NOZZLES: One of the Most Vital Elements Controlling the Process Characteristics
Continuously in Contact with the Abrasive Particles Moving at High Speed, therefore Nozzle Material should be
Very Hard to Avoid Significant Nozzle Wear
Commonly Used Nozzles in AJM Process
Material

Tungsten Carbide

Sapphire

Configuration

Round or Rectangular

Round only

Size

Rectangular: 0.07 x 0.5 mm to 0.17 x 3.8 mm

Round: Diameter from 0.12 to 1.25 mm

Nozzle Life

~ 30 Hours

~ 300 Hours

Cost

Sapphire Nozzles are Three to Eight Times More Expensive than Tungsten Carbide Nozzles

Nozzle Life is Defined by its Application. Exacting Operations (i.e. Cutting) Require Frequent Nozzle Changing
than Etching or Cleaning
STRAY CUTTING or OVERSPRAY: As the Nozzle Wears, the Jet Stream Tends to Diffuse Faster causing the
Damage to the Work Material Outside the Intended Line of Cut
Rectangular Nozzle Create Less Overspray Compared to Round Nones

[2.3.2] MASKS:
To Control Overspray or To Produce Large Holes and Intricate Details Without the Nozzle and Tracing the Shape
Mask is Produced with Areas Open where the Work Material is to be Removed. When AJM Stream is Passed
Over the Exposed Areas, Cutting or Etching takes Place on the Selective Basis
Masks can be Fabricated from Rubber or Metal
Rubber Masks are Easier to Fabricate but Give Poor Edge Definition.
Metal Masks Give Better Edge Definition but Erodes Faster
[3] SUMMARY of PROCESS CHARACTERISTICS and PARAMETERS of AJM PROCESS
Parameter

Common Value/Range

Mechanism of Material Removal

Brittle Fracture Caused by Impinging Abrasive Particles at High Speed

Abrasives

Al2O3, SiC: For Cutting, Cleaning, Deburring

Glass Beads: Matt Polishing and Cleaning
Dolomite:
Sodium Bicarbonate (Baking Soda): For Light Duty Applications such
as Cleaning, Etching, Deburring of Soft Materials
Abrasives are Not Reused

Carrier Gas

Type: Dry Air, Co2 (Most Commonly Used), N2, He, N2O [Never Use O2]
Pressure: 2 14 Bar; Velocity: 150-400 m/s; Quantity: 28 liter/min

Nozzle

Material: WC or Sapphire; Configuration/Shape: Round and Rectangular

Orifice Area: 0.05 0.3 mm2
Nozzle Tip or Stand-Off Distance (NTD or SOD): 0.25 75 mm
~ 0.8 mm (Cutting); 5 - 12.5 (Cleaning & Peening); 25-75 (Frosting)

Measures of Process Performance

MRR, Finish of the Cut, Geometry of Cut, and Nozzle Wear Rate

Critical
Process
Parameters

Mass Flow Rate of

Abrasives

1 30 g/min [0.0,000,167 0.0,005 kg/s]

Mean Diameter of
Abrasive Grains

0.01 0.15 mm

Velocity of Abrasive
Particles

150 400 m/s

A Minimum Value of Velocity (Known as Threshold or Critical Velocity)

[2.4] ABRASIVE COLLECTION SYSTEM:

To Maintain the Operators Exposure to Dusts within Permissible Limits
Vacuum Dust Collector can be Used to Draw Dust Particles from the Exhaust Chamber and Keep Operators
Viewing Clear
Special Considerations Must be Given to Dust Collection System Particularly if Toxic Materials Such as Beryllium
are being Abraded

[5] PARAMETRIC ANALYSIS: Important Process Parameters of AJM are

1. Related to Abrasives: Type, Size, Flow Rate, and Concentration (Mixing Ratio)
2. Related to Carrier Gas: Type, Pressure
3. Related to Nozzle: Shape, Size, SOD or NTD, Jet Velocity, and Wear Characteristics

[5.1.1] Effect of Abrasive Size (d): Finer Grains are Less Irregular in Shape Hence Possess Lesser Cutting
Ability. Finer Grains have more Tendency to Stick Together and Choke the Nozzle
Coarse Grains Cutting;
Finer Grains Polishing and Deburring, etc.
Finer Abrasive Grains can Cake in the Storage Tank and can Reduce Abrasive Mass Flow Rate. While
Oversize Particles can Clog the Nozzle. Best Results are Achieved Using Grain Size in 15 40 Range.

[5.1.2] Effect of Mass Flow Rate

and Concentration or Mixing Ratio

M

Ma

)of
: Abrasives

M a M air

Mass Flow Rate of Abrasive Particles Depends on the Pressure and Mass Flow of Carrier Gas as Shown in the Figure
As Abrasive Mass Flow Rate Increases, the MRR also Increases as More Abrasive Become Available for Cutting. But it also
Increases the Abrasive Concentration which in Turn Lowers the Velocity of Abrasive Particles and Tend to Reduce the MRR.
As a Combined Effect of it MRR Starts Decreasing After a Certain Value of Abrasive Mass Flow Rate

[5.2.1] Effect of Carrier Gas Pressure (P): The Composition and Pressure of the Carrier Gas Affects its
Velocity and Velocity of the Gas-Abrasive Stream.
MRR Increases with Increasing Gas Pressure at a Decreasing Rate and Tends to Saturate Beyond a
Certain Value.
The Critical Pressure Limit Depends on the Mixing Ratio. Higher Mixing Ratio Requires Higher Pressure
to Reach Sonic Velocity.
Higher Pressure Reduces the Nozzle Life

[5.3.1] Effect of Nozzle Tip Distance (NTD) or Stand Off Distance (SOD):
[5.3.1A] On Abrasive Jet Velocity ( v a ) : Figure 1 Shows that Velocity of Abrasive Particles Lags Sufficiently
Behind with that of Carrier Gas Velocity.
As Shown in the Figure 2, the Carrier Gas Attains the Maximum Velocity at the Nozzle Exit and Starts
Decreasing with Increasing SOD,
While Abrasive Particles Continue to Accelerate in the Jet Region and Attains Maximum Velocity at
Certain SOD (No Slip Condition) and then Starts Decreasing.
For Normal Impingement of Abrasive Particles, the Ductile Material Shows Lower MRR than Brittle
Materials for Same Velocity, but this Trend Reverses after a Certain Velocity [Figure 3]

[5.3.1B] On MRR: MRR Increases with an Increase in SOD till the Abrasive Particles Attains the Maximum
Velocity from the Nozzle Exit. Afterwards MRR Starts Decreasing thus Giving an Optimum Value of
SOD/NTD.
This Pattern of Curve is Essentially due to Inertia Effects of the Suspended Particles.

[5.3.1C] On Accuracy of Cut or Shape and Size of Cut: Accuracy of the Cut Decreases as the SOD
Increases due Spreading of the Jet.

[6] APPLICATIONS of AJM PROCESS

[6.1] MATERIALS APPLICATIONS:
Brittle Metals: Metals with BCC Structure such as W, V, Cr, Ta, Mo, etc. ;
Metals with HCP Structure such as Ti, Be, Co, Zr, Be, Cd,
Semiconductors: Operations such as Cutting, Drilling, Cleaning, Dicing, Beveling, Thinning can be done Accurately on
Semiconductors such as Silicon, Germanium, Gallium, etc.
Alloys: Superalloys
Ceramics: Glass, Quartz, Refractories, Insulators, Mica, etc.
Polymers: Plastics [Thermoplastics such as Nylon, Teflon], Rubber Stencils

[6.2] SHAPE APPLICATIONS:

Abrading and Frosting: AJM is Quicker than Acid Etching or Grinding

Making Threads on Glass Roods
Drilling Glass Baffers
Cutting: Cutting of Titanium Foil
Resistor Adjustment: AJM can Precisely Adjust Deposited and Wire-wound Resistors Through Accurate and
Controlled Removal of Conductive Material. Cutting is Faster and Gives Clean and Accurate Path
Micro-Module Fabrication: Abrasive Jet Cutting can Change Conductive Paths, Adjust Resistance or
Capacitance, or Shape Ceramics Precisely
Cleaning: Can be Used for Safe Removal of Metallic Smears on Ceramics, Oxides on Metals, Resistive Coatings,
etc. from the Parts too Delicate to Withstand Manual Scrapping or Powder Grinding
In Electrical Mfg. AJM can be Used to Remove Potting Material from Leads, Varnish from Potentiometer, etc.
Deburring: AJM can Remove Fine Burrs Faster and More Completely than Hand Filing Methods in Difficult-toReach Areas of Aerospace, Medical, and Computer Equipments.
Miscellaneous Metal Working Application: AJM can be Used to Drill and Cut Thin Sections of Hardened Metal;
Apply Trade Names to Parts; Remove Chrome, Corrosion, Contaminants , Anodized Finish from Small Areas; to
Produce Matt Finish
Deflashing Small Castings:
Grooving
Marking
Trimming
Engraving
Etching
Polishing
Testing Abrasion Resistance of Various Materials

Figures Showing Various Applications of AJM Process

[8] ADVANTAGES and LIMITATIONS of AJM PROCESS

[8.1] ADVANTAGES:

Can Machine Very Hard, Heat Sensitive, and Fragile Materials

Low Capital Cost i.e. One of the Least Expensive Non-Traditional Processes
Shockless Cutting Action by Abrasive Jet No Part Chatter or Vibration
Good for Difficult-to-Reach Areas

[8.2] LIMITATIONS:

Stray Cutting
Low MRR
Taper
Short Nozzle Standoff when Used for Cutting
Particles can Imbed into Workpiece

[7] SUMMARY of PROCESS CAPABILITIES and OPERATIONAL CHARACTERISTICS of AJM PROCESS

Type
Finishing
Capabilities

Capability/Characteristics
Surface Roughness [CLA in m]

0.2 0.8

Dimensional Tolerance or Accuracy [ m]

50 125

Minimum Corner Radii (mm)

0.2

Minimum Overcut (mm)

Depends on Stand Off Distance

Minimum Surface
Damage (m)

Drilling
Capabilities

Cutting
Capabilities

Economic
Aspects

Common Value/Range

Chemical Damage

No

Mechanical Damage

2.5

Thermal Damage

No

Hole Diameter (mm)

2.5 - 10

Aspect Ratio

0.1 2.5

Hole Depth (mm)

1.0 6.3

Minimum Taper (m /mm)

5.0

Maximum No. of Holes that can be Drilled

Simultaneously

Not Possible

Minimum Angle of Inclination Hole Axis with Surface

90o

Width of Cut (mm)

2.5

Thickness of Cut (mm)

1.5 6.3

Range of Cutting Rate (mm/min)

Data Unavailable

Initial Investment or Capital Cost

Very Low

Tooling and Fixtures Cost

Low

Power Consumption Cost

Medium

Tool Consumption Cost

Medium Tool Wear