Module 2
Abrasive Jet Machining(AJM):
Introduction
Equipment and process of material removal
Process variables: carrier gas, type of abrasives, work material,
stand off distance
Process characteristics-Material removal rate, nozzle wear,
accuracy & surface finish
Applications, advantages & limitations
Principles of abrasive jet
machining
• Abrasive Jet Machining (AJM) uses a high-velocity stream of abrasive particles carried in a gas
medium to remove material.
• Material removal occurs due to erosion caused by high-speed abrasive particles impacting the
work surface.
• Flowing gas (or air) carries away fractured particles, resulting in a smooth and fine surface finish.
• The process is similar to sandblasting but uses finer grit size abrasives.
• Abrasives are carried in a gas medium and impinge on the workpiece.
Need for AJM
• AJM is suitable for machining intricate shapes in hard and brittle
materials.
• It is effective for materials sensitive to heat.
• AJM can handle materials inaccessible by ordinary machining
methods.
• It is ideal for materials with a tendency to chip easily.
• These features make AJM a preferred process for such machining
tasks.
AJM EQUIPMENT
AJM Consists of:
•Nozzle
•Abrasive
•Carrier gas
•Metering system
a) Nozzle
•Accelerates abrasive particles onto the work
surface.
•Subjected to abrasion wear, so made from hard
materials like tungsten carbide or synthetic
sapphire.
b) Abrasive
• Common types: Aluminum oxide and silicon carbide.
• Silicon carbide is preferred for very hard materials.
• Particle size ranges from 10-50 µm.
• Smaller sizes for polishing and cleaning; larger for cutting
and peening.
• Must remain suspended and have good flow characteristics.
• Re-use is not recommended to avoid reduced cutting
capacity.
• Mass flow rate depends on gas pressure and flow rate.
c) Carrier Gas
• Air, nitrogen, or carbon dioxide is used.
• Must be filtered to remove contaminants.
• Pressure required is 2-8 kg/cm².
• Higher pressure increases nozzle wear; lower pressure
reduces removal rate.
d) Metering System
•Includes mixing chamber, regulator, and valves.
•Injects uniform abrasive flow into the gas stream.
•Uses a vibrating chamber for consistent powder
flow.
AJM Operation
• Filtered gas is supplied under pressure into the mixing chamber.
• The chamber contains fine abrasive particles.
• Vibrating action of the chamber entrains abrasives into the jet stream.
• The abrasive and gas mixture is passed into the nozzle.
• The mixture emerges from the nozzle at high velocity.
• Directed onto the work surface to be machined.
• Particle impact produces force to cut small holes or slots.
• Used for deburring, trimming, or removing oxides and surface films.
• Material removal occurs due to erosion or chipping.
• Nozzle is mounted on a fixture.
• Movement controlled by cams, pantographs, or other mechanisms.
• Dust hood or vacuum collector removes dust particles for clear visibility.
Process parameters(variables) of AJM
a) Abrasive Flow Rate and Velocity
• Increasing abrasive flow rate increases metal removal
rate.
• Flow rate above 14 g/min reduces abrasive velocity and
metal removal rate.
• Minimum jet velocity for erosion is 150 m/sec.
• Jet velocity depends on nozzle pressure, design,
abrasive size, and carrier gas abrasives.
b) Nozzle Tip Distance (NTD) or Stand-
off Distance (SOD)
• NTD is the distance between the nozzle tip and work
surface.
• Material removal rate increases with NTD up to 8 mm.
• Beyond 8 mm, removal rate decreases due to increased
drag.
• NTD above 8 mm useful for certain processes.
• Large NTD reduces accuracy of machined surface.
•MRR (Material Removal Rate): Measured in grams per
second (g/s) times 10⁴.
•NTD (Nozzle Tip Distance): Measured in millimeters
(mm).
Observations:
•Increasing NTD:
• As NTD increases from 0 to about 8 mm, MRR
increases.
• This indicates that the optimal stand-off distance
allows for effective impact of abrasive particles.
•Maximum MRR:
• Achieved around 8 mm NTD.
• Represents the point where abrasive particles are
most effective in removing material.
•Decreasing MRR:
• Beyond 8 mm, MRR decreases.
• Likely due to reduced energy and focus of particles
as distance increases.
Conditions:
• Abrasive oxide(Al2O3)
• Grain size: 40 microns
• Work material glass
• Pressure: 0.03N/mm2
•NTD (Nozzle Tip Distance): The distance
between the nozzle and the workpiece.
Observations:
1.NTD = 0.75 mm:
1. Diameter of Cut (d): 0.5 mm
2. Shape of Cut: Narrow and precise
3. Effect: Minimal flaring, high accuracy
2.NTD = 5 mm:
1. Diameter of Cut (d): 0.7 mm
2. Shape of Cut: Slightly wider
3. Effect: Moderate flaring, reduced accuracy
3.NTD = 10 mm:
1. Diameter of Cut (d): 1.5 mm
2. Shape of Cut: Much wider and less defined
3. Effect: Significant flaring, low accuracy
Key Points:
•Flaring Abrasive Jet: As NTD increases, the
abrasive jet flares out, leading to a wider cut.
•Machining Accuracy: Decreases with increased
NTD due to the spreading of the jet.
c) Abrasive Grain Size
•Ranges from 10-50 µm.
•Larger particles remove material faster.
•Coarse grains: Recommended for cutting.
•Fine grains: Used for polishing and deburring.
d) Mean Number of Abrasive Particles per Unit Volume of the Carrier Gas
•Defined by mixing ratio MM:
•Large MM increases metal removal rate.
•Excessive MM can reduce jet velocity or clog the nozzle.
•There is an optimum MM for maximum metal removal.
e) Nozzle Design
•Abrasive particles exit the nozzle at high velocity, causing abrasion wear.
•Wear-resistant materials like tungsten carbide and sapphire are used for nozzles.
•Nozzle design minimizes pressure loss from bends and friction.
•Nozzles can be circular or rectangular in cross-section with appropriate dimensions.
Process Capabilities of AJM
• a) Metal Removal Rate (MRR)
• Typical rate: 16 mm³/min in cutting glass.
• Minimum cut width: 0.1 mm using a rectangular nozzle with an orifice of 0.075 ×
1.5 mm at 0.08 mm distance from the surface.
• b) Accuracy
• Optimum conditions: Tolerance of ±0.05 mm.
• Normal production: Tolerance extends to 0.1 mm.
• c) Surface Finish
• Range: 0.4–1.2 µm.
• Depends on abrasive particle size and material.
• d) Corner Radius and Taper
• Corner radius limited to 0.1 mm.
• Taper: Around 0.05 mm per 10 mm of penetration.
Advantages
• Intricate Cutting: Suitable for hard, brittle, and heat-sensitive materials.
• No Vibrations: Uniform loading prevents chatter.
• Cost Efficiency: Low capital cost and power consumption.
Limitations
• Low Metal Removal Rate: Process is slower.
• Abrasive Embedding: High velocity can embed abrasives in the workpiece.
• Material Resistance: Resilient materials like rubber and some plastics resist
processing.
• Abrasive Reuse: Not possible.
• Short NTD: Can damage the nozzle during cutting.
Applications
• Material Machining: Effective for glass, quartz, semiconductors, and mica.
• Processes: Drilling holes, cutting slots, deburring, trimming, and oxide
removal.
METAL REMOVAL RATE (MRR) IN AJM
Limitations of AJM
•Low MRR: Slower and less suitable for large material removal.
•Surface Finish Issues: Can leave a rough surface.
•Nozzle Wear: Leads to inconsistency and higher costs.
•Poor for Soft Materials: Struggles to machine softer materials effectively.
•Health Hazards: Requires dust control and protective measures.
•Limited Depth and Geometrical Control: Lacks precision for deep or complex features.
•Not Ideal for Hard Metals: Performs poorly on tough materials.
•High Operational Costs: Ongoing costs for abrasives, nozzles, and safety measures.
•Limited for Thick Materials: Struggles with thick workpieces.
• Key Differences:
• Material Type: USM excels with brittle materials, while AJM is better
for hard, tougher materials.
• Machining Mechanism: USM uses ultrasonic vibrations and an
abrasive slurry, whereas AJM utilizes a high-velocity stream of
abrasive particles propelled by a gas.
• Summary:
• USM: Best for brittle materials (e.g., ceramics, glass) where precision
is essential.
• AJM: Best for hard materials (e.g., metals) where erosion-based
machining is advantageous.
