DESIGN AND F ABRICATION OF WORKING

MODEL OF ABRASIVE JET MAC HINE

Submitted in partial fulfillment of the requirements for the award of

BACHELOR OF TECHNOLOGY
IN
Mechanical Engineering
By
Name 1 Roll No
Name 1 Roll No
Name 1 Roll No
Name 1 Roll No

Under the Guidance of

[ ]

BBD
Affiliated to
Dr. A.P.J. Abdul Kalam Technical University Lucknow
SUBMITTED TO: …………………………
Contents
ABSTRACT.....................................................................................2
Introduction.................................................................................2
Literature survey:.........................................................................8
Cost calculation:.........................................................................18
Advantages:................................................................................18
Limitations:................................................................................18
Application:................................................................................19
ABSTRACT

Abrasive Jet Machining (AJM) is the process of material removal from a work piece
by the application of a high speed stream of abrasive particles carried in a gas or
air medium from a nozzle. The material removal process is mainly by erosion. The
AJM will chiefly be used to cut shapes in hard and brittle materials like glass,
ceramics etc. the machine will be automated to have 3 axes travel. The different
components of AJM are Compressor, Vibrator, dehumidifier, Pressure Regulator,
and Dust filter, Nozzle, Pressure gauge etc. The different components are selected
after appropriate design calculations.

In this project, a model of the Abrasive Jet Machine is designed using available
hardware and software etc. taking into consideration of commercially available
components. Care has been taken to use less fabricated components rather than
directly procuring them, because, the lack of accuracy in fabricated components
would lead to a diminished performance of the machine.

Introduction
Abrasive Jet Machining (AJM) is the removal of material from a workpiece by the
application of a high speed stream of abrasive particles carried in gas medium
from a nozzle. The AJM process differs from conventional sand blasting in that the
abrasive is much finer and the process parameters and cutting action are carefully
controlled.

The process is used chiefly to cut intricate shapes in hard and brittle materials
which are sensitive to heat and have a tendency to chip easily. The process is also
used for deburring and cleaning operations. AJM is inherently free from chatter
and vibration problems. The cutting action is cool because the carrier gas serves
as a coolant.

Equipment

A schematic layout of AJM is shown in Fig‐1. The filtered gas, supplied under
pressure to the mixing chamber containing the abrasive powder and vibrating at
50 c/s, entrains the abrasive particle and is the passed into a connecting hose. This
abrasive and gas mixture emerges from a small nozzle at high velocity. The
abrasive powder feed rate is controlled by the amplitude of vibration of the mixing
chamber. A pressure regulator controls the gas flow and pressure.

The nozzle is mounted on a fixture. Either the workpiece or the nozzle is moved by
cams pantograph or other suitable mechanisms to control the size and shape of
the cut. Hand operation is sometimes adequate to remove surface contaminations
or in cutting where accuracy is not very critical. Dust removal equipment is
necessary to protect the environment. Commercial bench mounted units
including all controls, motion producing devices, and dust control equipment are
available.
Fig. 1 Schematic layout of abrasive jet machine
The major components are:

1. Air compressor.
2. Air filter.
3. Dehumidifier.
4. Pressure Gauge.
5. Pressure Regulator.
6. Vibrator or Mixer.
7. Nozzle.
8. Arrangement to hold the work piece.
1.3 Different variables in Abrasive Jet Machine:

The variables that influence the rate of metal removal and accuracy of machining
in this process is:

1. Carrier gas
2. Types of abrasive
3. Size of abrasive grain
4. Velocity of abrasive jet
5. Flow rate of abrasive
6. Work material
7. Geometry, composition and material of nozzle
8. Nozzle work distance (stand off distance)
Characteristics of different Variables:

Medium Air , CO2 ,N2

Abrasive SiC, Al2O3 (of size 20µ to 50µ )

Flow rate of abrasive 3 to 20 gram/min

Velocity 150 to 300 m/min

Pressure 2 to 8 kg/cm2

Nozzle size 0.40 to 0.80 mm

Material of nozzle Tungsten carbide, Sapphire

Nozzle life 12 to 300 hr

Stand off distance 0.25 to 15 mm (8mm generally)

Work material Non Metals like glass, ceramics,

and granites.

Metals and alloys of hard materials

like germanium, silicon etc

Application Drilling, cutting, cleaning

Table 1 Characteristics of different variables

Literature survey:

The literature study of Abrasive Jet Machine reveals that the Machining
process was started a few decades ago. Till date there has been a through and
detailed experiment and theoretical study on the process. Most of the studies
argue over the hydrodynamic characteristics of abrasive jets, hence ascertaining
the influence of all operational variables on the process effectiveness including
abrasive type, size and concentration, impact speed and angle of impingement.
Other papers found new problems concerning carrier gas typologies, nozzle
shape, size and wear, jet velocity and pressure, stand‐off‐distance (SOD), or
nozzle‐tip‐distance (NTD). These papers express the overall process performance
in terms of material removal rate, geometrical tolerances and surface finishing of
work pieces, as well as in terms of nozzle wear rate. Finally, there are several
significant and important papers which focus on either leading process
mechanisms in machining of both ductile and brittle materials, or on the
development of systematic experimental‐statistical approaches and artificial
neural networks to predict the relationship between the settings of operational
variables and the machining rate and accuracy in surface finishing.

(Ref‐9)
The erosion of brittle materials by solid micro‐particles is a complex
process in which material is removed from the target surface by brittle fractures.
The rate of material removal is one of the most important quantities for a
machining process. Predictive mathematical models for the erosion rates in micro‐
hole drilling and micro‐channel cutting on glasses with an abrasive air jet are
developed. A dimensional analysis technique is used to formulate the models as
functions of the particle impact parameters, target material properties and the
major process parameters that are known to affect the erosion process of brittle
materials. The effect of various parameters like abrasive mass flow rate, air
pressure and standoff distance on erosion rate is shown by following graphical
presentation.
Effect of process parameters on erosion rate
(Ref‐10)
The AJM has been applied to rough working such as deburring and rough
finishing. With the increase of the needs for machining of ceramics,
semiconductors, electronic devices and LCD’s, micro‐AJM has become a useful
technique for micro machining. Experimental results showed good performance in
micro‐grooving of glass; however, the size of machined groove increased about 2–
4 µm. With the fine‐tuning the compensation for film wear, micro‐AJM could be
effectively applied to the micro‐machining of semiconductors, electronic devices
and LCD. The crack propagation during impact of abrasive particles on machining
material is given below:

Fig 3 Crack propagation during abrasive cutting of glass

Components and their design
Compressor

Compressor is a device that converts power (usually from an electric motor, a

diesel engine or a gasoline engine) into kinetic energy by compressing and
pressurizing air or gas which can be released according to use. In this project, a
reciprocating air compressor of 2kW is used to produce compressed air up to the
pressure of 150 psi and having storage tank which has storage capacity of 50 liters.

FR Unit (Dehumidifier):

The FRL Unit (Air Filter Regulator Lubricator unit) which is otherwise called
the moisture separator or dehumidifier is required for separating the moisture
from air. Atmospheric air always contains some water vapors in it. As the air with
high velocity is blown from the nozzle there is an abrupt rise in pressure which
converts water vapors into moisture. The moisture makes the abrasive particles to
agglomerate and this clogs the outlet of the Nozzle. To avoid this clogging
moisture separator should be used before abrasive particles are mixed with
compressed air. Different FRL Units are available commercially.
 OUTLET

INLET

Circulation of air

Separation of moisture

Fig. 4 Filter regulator unit

 The Vibrating Unit:

Vibrating Unit is used for mixing the air with the abrasive particles (Al2O3).
The Abrasive particles are stored in a container through which air is flown. The
particles are agitated by means of a cam and motor arrangement. The rotation of
cam results in vibration in the abrasive container. The flow rate of abrasive
materials can be controlled by manipulating the rotational speed of the motor.
The abrasive container will have one inlet and one outlet for air passage and will
be vertically suspended from a hinged joint. So the Vibrating Unit consists of
following parts –
i. Abrasive container
ii. Cam
iii. Induction Motor
(i) Abrasive container
Outlet
Inlet

Fig. 5 Abrasive container

 Abrasive container is fabricated by a hollow cylindrical thick metallic pipe of
60mm diameter and 140mm height. Two circular pipes of internal diameter
18mm is dipped from the top and welded, which would act as input for
compressed air and output for mixture of compressed air and abrasive
particles. The length of input pipe dipped is kept long to uniform circulation of
compressed air into the container.

(ii) Cam

Cam is fixed with shaft of the induction motor. The profile of the cam is
taken to be a circular one. The distance between two centers as shown in fig‐26
is 5mm. When the motor rotates; it makes the container to vibrate. Width of
cam is 35mm.

Fig. 6 Cam

(iii) Induction Motor

Induction motor used in this project is Single phase AC Induction motor of

0.5 watt. This motor is used to provide rotational motion to the Cam attached
with it. The installed induction motor has speed of 600 rpm.
Fig. 7 Vibration Assembly
Nozzle

A standard high carbon high chromium cylindrical rod was cut into required
length by power hack‐saw. The external diameter was then brought to 20mm by
turning it in lathe and then the tip was made by tapering one end by the same
lathe. A blind hole of approximate depth 25mm was made on the planner face of
the rod by means of a 12mm drill bit in a drilling machine. The end of the blind
hole forms a shape of 118 degree taper because of the tool tip angle. Internal
threading was made by 12mm tap. Then the tip of the nozzle is diameter drilled to
approximate diameter of 1mm

Threaded

1 mm hole

Fig. 8 Cut section of Nozzle Fig 9 Position of nozzle

Cost calculation:
S No. Name of Item Quantity Cost per unit Total cost of item

1. Reciprocating Air 1 8000 8000

compressor

2. FR unit 1 1200 1200

3. Abrasive container 1 400 400

4. Induction Motor 1 900 900

5. Abrasives 3 kg 50 150

6. Accessories - 2000 2000

7. Other expences - 1500 1500

TOTAL 14150

Advantages:
1. Low capital cost
2. Ability to cut intricate holes shape in materials of any hardness.
3. Ability to cut heat sensitive material without damage.
4. As no heat is generated in the process, no change in microstructure

Limitations:
1. Material removal rate is low and hence its application is limited.
2. Embedding of the abrasive in the work piece surface may occur while
machining softer material.
3. The abrasive material may accumulate at nozzle and fail the process if
moisture is present in the air.
4. It cannot be used to drill blind holes.
5. Occasional plugging of mixing tube: Usually caused by dirt or large particles in
abrasive.
6. Wear, misalignment, and damage to the nozzle.
Application:
The major application of Abrasive jet machining process is in the machining of
essentially brittle materials and heat sensitive materials like glass, quartz,
sapphire, semiconductor materials, mica and ceramics. It is also used in cutting
slot, thin sections, countering, drilling, for producing integrate shapes in hard and
brittle materials. It is often used for cleaning and polishing of plastics nylon and
Teflon components. Delicate cleaning, such as removal of smudges from antique
documents, is also easily done with Abrasive jet machining.