Professional Documents
Culture Documents
Dr. Venkaiah N
“A sacred thing is timely silence, and better than any
speech.”
- Plutarch
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Learning Outcomes
At the end of this lecture, student shall be able to
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Abrasive Jet Machining - Schematic
Gas Drier
supply
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AJM - Working
§ Carrier gas (Air/CO2/N2) is supplied at
high pressure (5 bar)
§ Oxygen should never be used.
(because, it causes violent chemical
action with the workpiece chips or
abrasive particles).
§ The gas is then passed through an air dryer to remove any residual
water vapour.
§ To remove any oil vapour or particulate contaminant, the gas is
passed through a series of filters.
§ Pressure regulator checks the working pressure of the carrier gas
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AJM - Working
§ Then the carrier gas enters a closed
chamber known as the mixing
chamber. The abrasive particles
enter the chamber from a hopper
through a metallic sieve.
§ The sieve is constantly vibrated by an electromagnetic shaker. The
mass flow rate of abrasive (15 g/min) entering the chamber
depends on the amplitude of vibration of the sieve and its
frequency (usually 50 Hz).
§ The abrasive particles are then carried by the carrier gas to the
machining chamber via an electromagnetic on-off valve.
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AJM - Working
§ The machining enclosure is
essential to contain the abrasive
and machined particles in a safe
and eco-friendly manner.
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Material Removal Mechanism
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AJM – Abrasives
§ Abrasive particles must be hard, highly tough and with sharp edges
§ Not reused
§ Shape à irregular
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Process Parameters
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Process Parameters
MRR, machining accuracy, surface roughness and nozzle wear are
influenced by
Carrier gas: Jet
• Type – Air, CO2, N2 • Velocity
• Pressure • Mixing ratio – Abrasive to Gas
• Flow rate mass flow ratio
• Stand-off distance
Abrasives: • Impingement Angle
• Type - Al2O3 , SiC, …
• Size Nozzle:
• Flow rate • Material – WC / sapphire
• Diameter
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Material Removal Rate (MRR)
§ Material or Volumetric Removal Rate (MRR or VRR) is given by the
formula
§ Typical MRR
o 1.6 to 4.1 mm3/min when cutting metals
o 16.4 mm3/min when cutting glass
o For harder ceramics, cutting rates are about 50 % higher than those for
glass à 24.6 mm3/min
§ The minimum width of cut à 0.13 mm 14
MRR
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Accuracy
Nozzle Tip Distance (NTD)
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Process Activity
§ List 4 process parameters
1. Abrasive flow rate
2. Gas pressure
3. Mixing ratio
4. Abrasive type and size
5. NTD or Stand off distance
§ Best suited for machining brittle, fragile and heat sensitive materials
like Glass, Silicon, Tungsten, Quartz, Sapphire, and Ceramics
§ Super-alloys and refractory materials can be machined
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Limitations/Drawbacks
§ Low MRR
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Applications
Metal working:
§ De-burring of some critical zones in the machined parts
§ Drilling and cutting of thin and hardened metal sections
§ Removing the machining marks, flaws, chrome and anodizing marks
Glass:
§ Cutting of the optical fibres without altering its wavelength
§ Cutting, drilling and frosting precision optical lenses
§ Cutting extremely thin sections of glass and intricate curved patterns
§ Cleaning and dressing the grinding wheels used for glass
Grinding:
§ Cleaning the residues from diamond wheels, dressing wheels
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Typical Part Geometries
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AJM - Summary
1. Mechanics - brittle fracture by impinging abrasive grains at high speed.
2. Media - Air, CO2
3. Abrasives: Al2O3, SiC, 0.025 mm diameter, 2-20 g/min, Not reused.
4. Velocity à 150-300 m/s
5. Pressure à 2 to 10 atm.
6. Nozzle à WC, sapphire; orifice 0.05-0.2 mm2, life 12-300 hr, SOD 0.25-75
mm.
7. Critical parameters à abrasive flow rate and velocity, SOD/NTD, abrasive
grain size and jet inclination.
8. Materials application à hard and brittle metals, alloys, and nonmetallic
materials (e.g., germanium, silicon, glass, ceramics, and mica).
9. Shape (job) application à drilling, cutting, deburring, etching, cleaning.
10. Limitations à low MRR (15 mm3/min), embedding of abrasive in workpiece,
tapering of drilled holes 23
Quiz
1. Material removal takes place in AJM due to
(a) electrochemical action
(b) mechanical impact
(c) fatigue failure of the material
(d) sparking on impact
Ans. (b)
Ans. (c)
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