Non Traditional Machining

Jagadeesha T, Assistant Professor. MED, National Institute of Technology, Calicut

ABRASIVE JET MACHINING

Definition:
In abrasive jet machining, a focused stream of abrasive 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 surface through a nozzle and work
material is removed by erosion by high velocity abrasive particles.

Process:
In Abrasive jet machining abrasive particles are made 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 converting pressure energy of carrier
gas or air to its Kinetic energy and hence high velocity 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 effectively 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 energy 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 stream
The particle are directed towards the focus of machining
As the particles impact the surface, it causes a micro fracture, and gas carries
fractured particles away
Brittle and fragile work better


Non Traditional Machining

Jagadeesha T, Assistant Professor. MED, National Institute of Technology, Calicut
Equipment:



A schematic layout of AJM is shown above. The gas stream is then passed to the
nozzle through a connecting hose. The velocity of the 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 carbon dioxide to propel the abrasive
particles. Gas may be supplied either from a compressor 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, easily 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 machining 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 and 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 Institute 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. Machining chamber is equipped with
vacuum dust collector. Special consideration should be given to dust collection
system if the toxic material (like beryllium) are being machined.

AJM nozzle
AJM nozzle is usually made of tungsten carbide or sapphire ( usually life 300 hours
for sapphire , 20 to 30 hours for WC) which has resistance to wear. The nozzle is
made of either circular or rectangular cross section and head can be head can be
straight, or at a right angle. It is so designed that 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 cutting and high inaccuracy.









Non Traditional Machining

Jagadeesha T, Assistant Professor. MED, National Institute 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. Selection 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 similar
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 necessary 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 Institute 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 WC


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 materials is possible.

Applications

1. This is used for abrading and frosting glass more economically 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 parts permanent marking on
rubber stencils, cutting titanium foils
4. Deflashing small castings, engraving registration numbers on toughened glass
used for car windows
5. Used for cutting thin fragile components like germanium, silicon etc.
6. Register treaming can be done very easily and micro module fabrication for
electrical contact , semiconductor processing can also 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 sensitive materials like glass, quartz,
sapphire , mica , ceramics germanium , silicon and gallium.
9. It is also good method for deburring small hole like in hypodermic needles and
for small milled slots in hard metallic components.

Advantages
1. High surface finish can be obtained depending upon 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 machine delicate and heat sensitive
material
4.Process is free from chatter and vibration as there 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 germanium, mica, silicon, glass and
ceramics can be machined.
7.It has the capability of cutting holes of intricate shape in hard materials.
Non Traditional Machining

Jagadeesha T, Assistant Professor. MED, National Institute of Technology, Calicut
Disadvantages /Limitations

1. Limited capacity due to low MRR. MRR for glass is 40 gm/minute
2 Abrasives may get embedded in the work surface, especially while machining soft
material like elastomers or soft plastics.
3. The accuracy of cutting is hampered by tapering of hole due to unavoidable flaring
of abrasive jet.
4. Stray cutting is difficult to avoid
5. A dust collection system is a basic requirement to prevent atmospheric pollution
and health hazards.
6. Nozzle life is limited (300 hours)
7. Abrasive powders cannot be reused as the sharp edges are worn and smaller
particles can clog the nozzle.
8. Short stand off distances when used for cutting , damages the nozzle.

Machining characteristics

Following are the AJM process criteria
1. Material removal rate
2. Geometry and surface finish of work piece
3. wear rate of the nozzle

Process criteria are generally influenced by the process parameters
The characteristics of above process parameters on process criteria are as follows

1.Effect of abrasive flow rate and
grain size on MRR
It is clear from the figure that at a
particular pressure MRR increase
with increase of abrasive flow rate
and is influenced by size of abrasive
particles. But after reaching
optimum value, MRR decreases with
further increase of abrasive flow
rate. This is owing to the fact that
Mass flow rate of gas decreases with
increase of abrasive flow rate and
hence mixing ratio increases causing
a decrease in material removal rate
because of decreasing energy available for erosion.

2. Effect of exit gas velocity and abrasive
particle density

The velocity of carrier gas conveying the abrasive
particles changes considerably with the change of
abrasive particle density as indicated in figure.

The exit velocity of gas can be increased to
critical velocity when the internal gas pressure is
nearly twice the pressure at exit of nozzle for the
abrasive particle density is zero. If the density of
Non Traditional Machining

Jagadeesha T, Assistant Professor. MED, National Institute of Technology, Calicut
abrasive particles is gradually increased exit velocity will go on decreasing for the
same pressure condition. It is due to fact that Kinetic energy of gas is utilized for
transporting the abrasive particle

3.Efect of Mixing ratio on MRR

Increased mass flow rate of abrasive will result in a
decreased velocity of fluid and will thereby decreases
the available energy for erosion and ultimately the
MRR. It is convenient to explain to this fact by term
MIXING RATIO. Which is defined as

Mixing ratio =



The effect of mixing ratio on the material removal rate is shown above.

The material removal rate can be improved by
increasing the abrasive flow rate provided the mixing
ratio can be kept constant.The mixing ratio is
unchanged only by simultaneous increase of both gas
and abrasive flow rate.

An optimum value of mixing ratio that gives maximum
MRR is predicted by trial and error. In place of Mixing
ratio, the mass ratio ( ) may be easier to determine.
Which is defined as
= =
.
.
g a
a
m
m
+


3.Effect of Nozzle pressure on MRR

The abrasive flow rate can be increased by
increasing the flow rate of the carrier gas.
This is only possible by increasing the internal
gas pressure as shown in the figure. As the
internal gas pressure increases abrasive mass
flow rate increase and thus MRR increases.

As a matter of fact, the material removal rate
will increase with the increase in gas pressure

Kinetic energy of the abrasive particles is
responsible for the removal of material by
erosion process. The abrasive must impinge on the work surface with minimum
velocity for machining glass by SIC particle is found to be around 150m/s.




Volume flow rate of carrier gas
Volume flow rate of carrier gas
Mass flow rate of carrier gas
Mass flow rate of carrier gas and abrasive
Non Traditional Machining

Jagadeesha T, Assistant Professor. MED, National Institute of Technology, Calicut























5. Stand off distance.

Stand off distance is
defined as the distance
between the face of the
nozzle and the work
surface of the work. SOD
has been found to have
considerable effect on the
work material and
accuracy. A large SOD
results in flaring of jet
which leads to poor
accuracy.

It is clear from figure that
MRR increase with nozzle
tip distance or Stand off
distance up to certain distance
and then decreases.
Penetration rate also increases
with SOD and then decreases.
Decrease in SOD improves
accuracy, decreases kerfwidth,
and reduces taper in machined
groove. However light
operation like cleaning, frosting
etc are conducted with large
SOD.(say 12.5 to 75mm)

Non Traditional Machining

Jagadeesha T, Assistant Professor. MED, National Institute of Technology, Calicut
Material removal models in AJM

Following assumptions are made in deriving the Material removal models for AJM.
1. Abrasive are spherical in shape and rigid
2. Kinetic energy of particle is completely used to cut the material
3. Brittle material are considered to fail due to brittle fracture and fracture of volume
is considered to be hemispherical with diameter equal to chordal length of
indentation
4. For Ductile material volume of material removal is assumed to be equal to
indentation volume due to particulate impact.

Abrasive particles are assumed to be spherical in shape having diameter d
g.


From the geometry

AB
2
= AC
2
+ BC
2


2
2
2 2
r
d d
g g
+
|
|

\
|
=
|
|

\
|

2
2
2 2
r
d d
g g
=
|
|

\
|

|
|

\
|


r
2
= -
g
d +
2
Neglecting
2
term we
can write
r =
g
d


For Brittle material

Volume of the material removed is the volume of the hemispherical crater due the
fracture is given by

Volume of the material removed

(

=
3
r
3
4
2
1

B
= ( )
(

2
3
r
3
4
2
1
=
( )
(

2
3

3
2

g
d
--------------------------------(1)
Non Traditional Machining

Jagadeesha T, Assistant Professor. MED, National Institute of Technology, Calicut

Let us assume that grits also move with velocity (V) then we can write

Kinetic Energy = KE = ( )
(

2
M
2
1
V = ( )
(

\
| 2 3

6 2
1
V d
g g

--------------------------(2)

On impact , work material would be subjected to maximum force F, Which would
leads to indentation of .

Work done during such indentation is
W D by the grit = F
2
1
-------------------------------------------------------------(3)
Also we know the Flow strength of material =
2
r
F
w

= or F =
2
r
w
--------(4)
F = ( )
2

g w
d

Using equation (4) in (3) we get.

W D by the grit = F
2
1
=
( )
2

g w
d


It is assumed that Kinetic energy of the abrasives is fully used for material removal

Kinetic energy of the particle = W D by the particle

( )
(

\
| 2 3

6 2
1
V d
g g

=
( )
2

g w
d

Simplifying we get

w
g

6
d V
g
= ------------------------------------------------------------------------(5)

MRR in AJM material can be expressed as

MRR =

second per abrasives

by made impacts
.
of Number
cycle per grit per
removed
material the of Volume
X

MRR =
grit abrasive the of Mass
abrasives of rate flow Mass
x
(

B




Non Traditional Machining

Jagadeesha T, Assistant Professor. MED, National Institute of Technology, Calicut
=
( )
(

2
3

3
2

g
d
x
( )
g g
a
d
M

3
6

Upon simplifying we get

MRR =
( ) ( )
(
(
(

4
3
4
1
w g
a
M



For ductile material

( ) ( ) [ ]
2

2
1

g D
d =

MRR =
grit abrasive the of Mass
abrasives of rate flow Mass
x
(

D


Substituting and simplifying we get.
MRR =
(

W
a
M
2
V
2



Problem 1 : Estimate the MRR in AJM of a brittle material with flow strength of 4
GPA. The abrasive flow rate is 2 gm/min, velocity is 200m/s, density of abrasive is 3
gm/sec.

Data Given:

Flow strength of work material =
2 2 9
/ 4000 N/m 10 4 mm N x
w
= =
Abrasive grain density = 3gm/CC = 3x10
-3
x10
-3
= 3x10
-6
kg/mm
3

Mass flow rate of abrasives
g
= 2gm/min = 2x 10
-3
/60

kg/sec
Velocity = V = 200x1000mm/sec

Solution

Since the material is brittle. We need to use the MRR formula corresponding to
The brittle material.

MRR
Britlle
=
( ) ( )
(
(
(

4
3
4
1
w g
a
v M

=
( ) ( )
(
(
(

4
3
9
4
1
6
2
3
3
10 4 10 3
200000 10 2
x x
x x


=48 mm
3
/minutes



Non Traditional Machining

Jagadeesha T, Assistant Professor. MED, National Institute of Technology, Calicut
Problem 2 : Material removal rate in AJM is 0.5 mm
3
/sec. calculate MRR/impact if
the mass flow rate of abrasive is 3gm/min, density is 3 gm/CC and grit size is 60
microns . Also calculate the indentation radius.

Data Given:
Material removal rate = 0.5 mm
3
/sec.
Abrasive grain size = 60 microns = 6x10
-3
mm
Mass flow rate of abrasives
g
= 3gm/min = 3x 10
-3
/60

kg/sec
Mass of grit =
(

\
|

6
3
g g
d

MRR = Volume of the material removed x
grit abrasive of Mass
abrasives of rate flow Mass

0.5x10
-6
= ( )
3
3
2
r x
(
(
(
(
(

\
|
6 -
3
10 x 1000
3
10000
60
6
60 x 1000
3

= 10 microns

MRR =

second per abrasives

by made impacts
.
of Number
cycle per grit per
removed
material the of Volume
X


Number of impact/time =
( )
(
(
(
(

3000 10 50
60
10 3
6
3
6
3
x x x
x
x

= 254648
Problem 3: During AJM , Mixing ratio used is 0.2. calculate Mass ratio, if the ratio of
density of abrasives and density of carrier gas is equal to 20.

Solution :
Mixing ratio(MR) =
gas carrier of rate flow Volume
particle abrasive of rate flow Volume

Mass ratio( ) =
gas carier and abrasive of rate flow mass combined
rate flow mass Abrasive

MR =
g
a
V
V
.
.
also
g
.
a
.
a
.
g a
a
V V
V
M
M

g a
a

+
= =
+


Or =

1
a
.
g
.
a
.
V
V V
a
g a

+
= 1+
(
(

a
g
a
g
V
V
.
.

=
2 . 0
1
20
1
1 x +

i.e =

1
1.2 5 or 80 . 0 =

Non Traditional Machining

Jagadeesha T, Assistant Professor. MED, National Institute of Technology, Calicut
Problem 4: Diameter of nozzle is 1.0mm and jet velocity is 200m/s. Find the
volumetric flow rate ( cm
3
/sec ) of carrier gas and abrasive mixture.

Cross sectional area of nozzle = ( )
2 4 2 2
10 25 10 5 . 0 cm x x x x

=

Volumetric flow rate of carrier gas and abrasive mixture is = area x velocity
= 2 25x x
= 50 cm
3
/Sec

Practice Problem

1.Find out the condition for which AJM will produce equal MRR both for ductile and
brittle materials. ( Hint : equate MRR equations and find the condition for critical
velocity)

2.Material removal rate in AJM is 0.3 mm
3
/sec. calculate MRR/impact if the mass
flow rate of abrasive is 4gm/min, density is 1.5 gm/CC and grit size is 23 microns
Also calculate the indentation radius

3During AJM , Mixing ratio used is 0.3. Calculate Mass ratio, if the ratio of density
of abrasives and density of carrier gas is equal to 10

Give reasons for the following
1. Abrasive machining is not suitable for soft materials
2. Working temperature should be less than 50
oc
if we use Sodium bicarbonate
abrasive particle
3. Abrasive particles in AJM cannot be reused.
4. Dust collection system is needed for Abrasive jet machining of beryllium
5. In AJM, MRR for ductile material is lower than Brittle materials.

Review Questions
1. With the help of neat diagram explain Abrasive jet machining system
and label the parts.
2. What are the advantages and limitations of AJM?
3. Discuss the effect of following process parameters on MRR
SOD and MRR
Effect of abrasive grain size and flow on MRR
Effect of Nozzle pressure for various MR on MRR
Effect of Mixing ratio on MRR
6. Derive an expression for MRR in AJM for brittle material
7. Write at least five application of AJM in Industry
8. State clearly the process capability of AJM
9. Define AJM. What is the principle of Abrasive jet machining
10. Write the applications of different types of abrasives used in AJM.
11. Write five important variables of AJM process. Draw a sketch showing the effect
of these variables on MRR
12. Explain the working principle of AJM process
13. With the help of sketches, show the effect of stand off distance on MRR.