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
 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
A schematic layout of AJM
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 m3/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
 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.
 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.
 ABRASIVES

Aluminum oxide (Al2O3) 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.
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
Process criteria are generally influenced by the process parameters as
enumerated below:
Abrasives
a) material – Al2O3 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/m3
c) Velocity - 500 to 700 m/s
d) Pressure - 2 to 10 bar
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.

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 cm3/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
6. Used for drilling , cutting , deburring etching and polishing of
hard and brittle materials.
7. Most suitable for machining brittle and heat sensitive
materials like glass, quartz, sapphire , mica , ceramics
germanium , silicon and gallium.
8. 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

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.
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.
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
 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 abrasive particles is gradually
increased exit velocity will go on decreasing for
the same pressure condition.
 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
 4.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
esponsible for the removal of material by
erosion process.
 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)
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
4. Derive an expression for MRR in AJM for brittle material
5. Write at least five application of AJM in Industry
6. State clearly the process capability of AJM
7. Define AJM. What is the principle of Abrasive jet machining
8. Write the applications of different types of abrasives used in AJM.
9. Write five important variables of AJM process. Draw a sketch showing the effect of these
variables on MRR
10. Explain the working principle of AJM process
11. With the help of sketches, show the effect of stand off distance on MRR.
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Water Jet Machining (WJM)
 Water Jet Machining (WJM) also called water jet cutting, is a
non-traditional machining process in which high-velocity jet of
water is used to remove materials from the surface of the
workpiece.
 WJM can be used to cut softer materials like plastic, rubber or
wood.
 In order to cut harder materials like metals or granite, an
abrasive material is mixed in the water.
 When an abrasive material is used in the water for the
machining process then it is called Abrasive Water Jet
Working Principle

 It is based on the principle of water erosion. When a

high-velocity jet of water strikes the surface, the removal
of material takes place.
 Pure water jet is used to machine softer materials. But to
cut harder materials, some abrasive particles mixed with
the water for machining and it is called as AWJM
(Abrasive Water Jet Machining)
Abrasive Materials
 The most commonly used abrasive particles in AWJM are
garnet and aluminum oxide.
 Sand (Si02) and glass beads are also used as abrasive.
 The function of the abrasive particles is to enhance the
cutting ability of the water jet.
The various parts of water jet machining are
1. Hydraulic Pump
It is used to circulate the water from the storage tank during the
machining process. The pump delivers water to the intensifier at low
pressure of about 5 bars. A booster is also used which increases the
initial pressure of water to 11 bar before delivering it to the intensifier.
2. Hydraulic Intensifier
It is used to increase the pressure of water to very high pressure. It
receives the water from the pump at 4 bar and increases its pressure up
to 3000 to 4000 bar.
3. Accumulator
It stores the high pressurized water temporary. It supplies that fluid
4. Mixing chamber or tube
It is a vacuum chamber where the mixing of abrasive particles into water
takes place.

5. Control Valve:
It controls the pressure and direction of the water jet.

6. Flow Regulator or Valve

The flow of the water is regulated with the help of the flow regulator.
7. Nozzle
It is a device that is used to convert the pressure energy of water into
kinetic energy in water jet machining. Here nozzle converts the pressure
of water jet into high-velocity beam of water jet. The tip of the nozzle is
made of ruby or diamond to prevent it from erosion.

8. Drain and Catcher System

After the machining, the debris and machined particles from the water
are separated out with the help of the drain and catcher system. It
removes the metal particle and other unwanted particles from the water
and sends it back to the reservoir for further use.
 Working of Water Jet Machining
 The water from the reservoir is pumped to the intensifier with the
help of a pump.
 The intensifier increases the pressure of the water from 5 bars to
3000 to 4000 bar.
 This high-pressure water from the intensifier is moved to the
nozzle as wells as in accumulator.
 The accumulator stores the high-pressure water and supplies it at
any instant when it is required.
 It is used to eliminate the fluctuation of the high-pressure
requirement of machining hard material.
 A very high-velocity jet of water (1000 m/s) comes out through the nozzle in the
form of a narrow beam.
 Abrasive such as garnet or aluminum oxide is mixed with water within the
nozzle.
 A mixing chamber is there in the nozzle where the abrasives get mixed with the
high-pressure water.
 This high-velocity jet of water when strikes the surface of the w/p removes the
material from it.
 The water jet after machining it gets collected by the drain and catcher system.
Here the debris, metal particles from the water are removed and it is supplied
to the reservoir tank.
 The working will same for the water jet machining but abrasive particles are not
mixed with the high-velocity jet.

 Advantages

 It has the ability to cut materials without disturbing its original

structure. And this happens so because there is no heat-affected zone
(HAZ).
 It is capable of producing complex and intricate cuts in materials.
 The work area in this machining process remains clean and dust-free.
 It has low operating and maintenance cost because it has no moving
parts.
 The thermal damage to the workpiece is negligible due to no heat
generation.
 It is capable of cutting softer materials (WJM) like rubber, plastics or
wood as well as harder material (AWJM) like granite.
 Disadvantages

 It is used to cut softer materials.But AWJM can cut harder material of

limited thickness.
 Very thick material cannot be machined by this process.
 The initial cost of WJM is high.
Application

 Water jet machining is used in various industries like mining,

automotive and aerospace for performing cutting, shaping and
reaming operations.
 The materials which are commonly machined by water jet (WJM
or AWJM) are rubber, textiles, plastics, foam, leather,
composites, tile, stone glass, food, metals/ paper and much
more.
 WJM is mostly used to cut soft and easy to machine materials
such as thin sheets and foils, wood, non-ferrous metallic alloys,
textiles, honeycomb, plastics, polymers, leathers, frozen, etc.
 AWJM is typically used to machine those materials which are hard
and difficult to machine.
 It is used to machine thick plates of steel, Al and other commercial
materials, reinforced plastics, metal matrix, and ceramic matrix
composites, layered composites, stones, glass, etc.
 Besides the Machining process, the high-pressure water jet is used
in paint removal, surgery, cleaning, peening to remove residual
stress, etc.
 AWJM can also be used to perform drilling, pocket milling, turning
and reaming.
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Differences between WJM & AJM
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Problems
1. Assuming no losses, determine water jet velocity, when the water
pressure is 4000 bar, being issued from an orifice of diameter 0.3
mm
2. Determine the mass flow rate of water for the given problem
assuming all related coefficients to be 1.
3. If the mass flow rate of abrasive is 1 kg/min, determine the
abrasive water jet velocity assuming no loss during mixing process
using the above data (data of Question. 1, 2 and 3)
4. Determine depth of penetration, if a steel plate is AWJ machined
at a traverse speed of 300 mm/min with an insert diameter of 1
mm. The specific energy of steel is 13.6 J/mm3
.