DESIGN AND ANALYSIS ON AJM

NOZZLE

A Mini Project Report

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE

AWARD OF THE DEGREE OF

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
SUBMITTED BY

P.V.NICHITHA [15K81A03A7]
A.NAVEEN KUMAR [15K81A0361]
D.SAJJAN GOUD [15K81A0379]
Y.VAMSI [15K81A03B8]

SUPERVISED BY

PROF.D V SREEKANTH

AUGUST 2018

DEPARTMENT OF MECHANICAL ENGINEERING

St.MARTIN’S ENGINEERING COLLEGE
DHULAPALLY- SECUNDERABAD, TELANGANA (INDIA)-500010

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 St.MARTIN’S ENGINEERING COLLEGE
(Approved by A.I.C.T.E, New Delhi, NBA Acc redited, Affiliated to JNTU Hyderabad)

DHULAPALLY-SECUNDERABAD, TELANGANA (INDIA)-500010

CERTIFICATE

This is to certify that the mini project report entitled “DESIGN OF AJM
NOZZLE” is submitted by “P.V.NICHITHA- 15K81A03A7” in partial
fulfillment of the requirements for the award of the Degree of Bachelor of
Technology in Mechanical Engineering. to the Jawaharlal Nehru
Technological University, Hyderabad as a record of bonafide work done by her
under our supervision and guidance.

Guide head of the department

BHOJENDRA NAIK D V SREEKANTH

ASST.PROFESSOR HOD,MECHANICAL DEPT.

Internal Examiner External Examiner

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 ACKNOWLEDGEMENT

I would like to place on record my deep sense of gratitude to

ASST.PROF.BHOJENDRA NAIK Dept. of Mechanical Engineering, SMEC,
Secunderabad for his generous guidance, help and useful suggestions.

I express my sincere gratitude to PROF.D V SREEKANTH, Head, Dept. of

Mechanical Engineering, SMEC,Secunderabad, for his stimulating guidance,

continuous encouragement and supervision throughout the course of present

work.

I also wish to extend my thanks to prof.CH RANGARAO and other colleagues

for attending my seminars and for their insightful comments and constructive

suggestions to improve the quality of this research work.

I am extremely thankful to SANTOSH KUMAR PATRA, Principal, SMEC, for

providing me infrastructural facilities to work in, without which this work

would not have been possible.

P.V.NICHITHA D.SAJJAN A.NAVEEM Y.VAMSI

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 ABSTRACT
The abrasive jet machining is a method based on the effects of the fine abrasive

particles transported and directed to the work piece surface by means of

compressed air jet. When the dimensions of the machined surface are lower

than one millimeter, the abrasive jet machining could be included in the group

of micromachining processes. The nozzle shape, size, nozzle tip distance are the

most important parameters in abrasive air-jet machining equipment. Materials

with high wear resistance will have great potential as abrasive air-jet nozzle

materials. In this abstra paper, a Tungsten Carbide, Sapphire, Stainless steel, and

(W,Ti)C/SiC gradient ceramic composite nozzles along with nozzles of different

design which was developed has been studied.

The erosion wear behavior of the nozzle was investigated and compared with a

conventional ceramic nozzle. Results showed that the gradient ceramic nozzles

exhibited an apparent increase in erosion wear resistance over the conventional

ceramic nozzles. The mechanism responsible was found to be that the tensile

stresses at the entry region of the nozzle were greatly reduced when compared

with the conventional nozzle.

This effect may lead to an increase in resistance to fracture, and thus increase

the erosion wear resistance of the gradient nozzle.

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 CONTENTS

ACKNOWLEDGEMENT 3

ABSTRACT 4

CHAPTER – 1 7

INTRODUCTION 7

1.1.DEFINITION AND PROCESS 8

1.2 Principle of AJM: 8

1.3 Process description: 9

1.4 EQUIPMENT 11

1.5 AJM NOZZLE 11

1.7 abrasive particles 12

1.8 applications 12

1.9.1 advantages 14

1.9.2 disadvantages 14

CHAPTER – 2 15

LITERATURE REVIEW 15

CHAPTER 3 18

DESIGN PROCEDURE 18

3.1 NOZZLE MATERIAL AND DESIGN 18

3.2 OPTIMUM PROCESS PARAMETERS 24

CHAPTER – 4 26

RESULT AND DISCUSSIONS 26

4.1Process capability of abrasive jet machining 26

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 4.2Material removal rate and its estimation 27

4.3.1Effect of impingement angle on AJM performance 29

4.3.2Effect of stand-off distance on AJM performance 29

4.3.3Effects of mixing ratio on AJM performance 30

4.3.4Effects of carrier gas on AJM performance 30

4.3.5Effects of abrasives on AJM performance 31

CHAPTER – 5 32

CONCLUSION 32

REFERENCES 33

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CHAPTER – 1

INTRODUCTION

Abrasive Jet Machining (AJM) is the process of material removal from a

workpiece by the application of a high speed stream of abrasive particles

carried in a gas medium from a nozzle. There are two types of abrsive jet

machining setup available. Abrasive jet machining (AJM) is a process of

material removal by mechanical erosion caused by the impingement of high

velocity abrasive particles carried by a suitable fluid (usually a gas or air)

through a tailer made shaped nozzle on to the work piece. An AJM set-up

may be of two types: one a vortex-type mixing chamber and the other using a

vibratory mixer. In the former, abrasive particles are carried by the vortex

motion of the carrier fluid, whereas in the latter type abrasive particles are

forced into the path of the carrier gas by the vibratory motion of the abrasive

particle container. The erosion phenomenon in an AJM may bestudied in two

phases. The first consists of transportation phase, i.e. the quantity of abrasive

particles flown, and the direction and velocity of impinging particles as

determined by the fluid flow condition of solid-gas suspension. The second

phase of the problem is the determination of the material removal rate or the

erosion.

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1.1.DEFINITION AND PROCESS
Definition:

In abrasive jet machining,an engaged stream of rough particles,conveyed by

high weight air or gas is made to encroach on the work surface through a

nozzle and the work material is made to encroach on the work surface through

a nozzle and work material is evacuated by disintegration by high speed rough

particles.

Process:

In abrasive plane machining grating particles are made to encroach on work

material at high speed. Plane of rough particles is conveyed via transporter

gas or air. The high speed stream of abrasives is created by changing over

weight vitality of bearer gas or air to its kinetic vitality and consequently high

speed plane. Nozzles coordinates rough stream in a controlled way onto work

material. The high speed grating particles evacuate the material by small scale

cutting activity and in addition fragile crack of the work material.

1.2 Principle of AJM:

AJM is also named as abrasive micro blasting, is a nonconventional

machining process that carried a high-pressure air stream with small

abrasive particles to impinge the work surface through a nozzle for material

removal of the work piece.The material removal occurs by the erosive action

of the abrasive particles striking the work piece surface. The material removal

capability of AJM is very low so it is used in a finishing process. It is as an

effective machining method for hard and brittle materials . and it’s it is similar

to sand blasting process but difference is finer abrasive powders and smaller

nozzles are used in AJM.

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1.3 Process description:
carrier gas is compressed at a high pressure in an air compressor. Gases like

dry air, CO 2, N 2 are used as a carrier gas. At first the carrier gas is passed

through a pressure regulator to obtain the desired working pressure. The gas

is then passed through a FRL unit (filter lubricator and regulator). This unit

removes dust particle and also lubricate and regulate the flow of carrier gas.

After that the carrier gas enters into the mixing chamber. The abrasive

particles placed in the abrasive container. Abrasive particle are enter into the

mixing chamber as per our requirement by the application of vibrator.

The abrasive particles are then carried by the carrier gas from the mixing

chamber to work piece through nozzle. The total machining process is

enclosed for safe and ecofriendly purpose.

The major components are:

Compressor.

FRL unit

Pressure Gauge.

Pressure Valve.

Abrasive Container.

Vibrator or Mixer.

Nozzle.

Enclosure

Work Piece

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 Abrasive Powder

The process parameter and its standard value are in given that is required

for experimental work.

Process parameter and its standard value

Abrasive powder:

Shape : Irregular or spherical

Size : 10-50µm

Flow rate: 5- 20 gm/min

Material: AL 2 O 3 , SiC

Carrier gas:

Composition : Air, CO 2 , N 2

Velocity : 500-700 m/s

Pressure : 2-10 bar

Flow rate : 5-30 lpm

Abrasive et:

Velocity : 100-300 m/s

Mixing ratio : Mabr/Mgas

Stand-off distance : 0.5-5 mm

Impingement angle : 60 0 -90 0

Nozzle:

Material : Tungsten carbide, boron carbide, sapphire

Diameter : 0.2-0.8 mm

Life : 10-300 hrs

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1.4 EQUIPMENT

1.5 AJM NOZZLE

A schematic format of AJM nozzle is appeared previously. The gas stream is then gone to the

nozzle through an associating hose. The speed of the grating stream shot out through the nozzle

is for the most part of the request of 330 m/sec.

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1.7 abrasive particles
In AJM, it is assumed that hard abrasive particles participate in material

removal action, while carrier gas assists to blow away eroded particles from

machining zone. Such abrasives must possess few basic properties for

efficient removal of material as well as to get desired quality of cut. Among the

desired properties sufficient hardness, irregular shape, presence of sharp

edges and good flow characteristics are essential.Different abrasives having a

range of grit size can be utilized based on

workpiece material and the operation it is intended to perform. Aluminum

oxide (alumina) of average grit size 10 – 50µm is commonly used for grooving

and drilling operation, especially when work material is hard. However, for

very hard work material, silicon carbide (SiC) is preferred as it is harder than

alumina. For polishing and coating removal purposes, glass beads and

crashed glass are conventionally used. Size of abrasives also influences

quality of cut as well as material removal rate. Larger grit size tends to

produce larger cavity and thus MRR improves with the sacrifice of surface

finish. On the other hand, fine abrasives reduce MRR but improve surface

quality and accuracy.

1.8 applications

• Abrasive jet machining can be advantageously utilized for multifarious

purposes including surface cleaning, deburring, abrading and even

making holes. Common applications of abrasive jet machining process

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 are provided below. It is to be noted that, irrespective of the purpose,

abrasive jet machining (AJM) is beneficial only for hard and brittle

materials. AJM should be avoided if work material is soft and ductile;

otherwise quality of machined surface will be poor.

• Work surface cleaning—AJM can be advantageously used for cleaning

metallic or ceramic surfaces (substrate must be hard). Such cleaning

processes include removal of oxide, paint, coating, stain, glue, loose

sand particles, etc.

• Deflashing and trimming—Controlled abrasive jet machining can be

utilized for removing flash to get desired clean product with higher

dimensional accuracy and tolerance as well as sumptuous appearance.

• Engraving—As an alternative to laser beam machining, abrasive jet

machining can also be applied for incising purposes irrespective of

chemical and electrical properties of work material.

• Ceramic abrading and glass frosting—Very hard materials including

glass, refractory, stone, etc. can be easily abraded by AJM in order to

get finished surface having tight tolerance.

• Deburring—Abrasive jet machining is one of the efficient methods for

deburring (process for removal of burr) of milled features and drilled

holes, especially when work material is hard.

• Cutting and drilling hole—AJM can also be utilized for cutting various

shapes as well as for drilling holes. However, holes, slots or pockets may

lack accuracy as sharp corners cannot be obtained by this process.

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1.9.1 advantages
• Suitable for removal of deposits on surface

• Wide range of surface finish can be obtained

• Process is independent of electrical or thermal properties

• No thermal damage of workpiece

• Suitable for nonconductive brittle material

• Low capital investment

1.9.2 disadvantages

• Not suitable for soft and ductile materials

• Abrasives are not reusable

• Abrasive collection and disposal are problematic

• Inaccurate cutting and drilling (stray cutting)

• Limited nozzle life

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CHAPTER – 2

LITERATURE REVIEW

The literature survey of Abrasive Jet Machine says that the Abrasive

JetMachining process was started a few decades ago. Till today experimental

andtheoretical study on the Abrasive Jet Machining process occurs. Most of

thestudy based upon experiment. Some of the study based upon modeling

and

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analysis.Ke et.al has designed a novel hybrid method, called flexible

magneticabrasive jet machining, for investigating the machining

characteristics of theself-made magnetic abrasive in abrasive jet machining.

According to Taguchimethod conclusion was derived that flexible magnetic

abrasive particle givesbetter MRR and surface roughness than traditional

abrasive.Wang and fan [2] represented a theoretical analysis and associated

with mathematical models for the velocity of abrasive particles in an abrasive

air jetmachining. By using the Bernoulli’s equation of compressible of flow jet

airvelocity was calculated. Considering particle mean diameter, nozzle length,

airdensity and air flow velocity particle velocity at the nozzle exit is

determined.

Also modeled the distribution of particle velocities along the jet

centerlinedownstream from the nozzle and the particle velocity profile at a jet

cross-section by considering surrounding air entrainment and air-particle

interaction.After comparing the experimental result with theoretical

calculation, it wasshown that less than 4% error was occurred.Gradeena et.al

[3] used a cryogenic abrasive jet machining apparatus forsolid particle erosion

of polydimethylsiloxane (PDMS) using aluminum oxide

as an abrasive at a temperature range between -178 0 C to 17 0 C. He

observed thatoptimum machining of PDMS occurred at temperature

approximately at -178 0 Cand the attacking angle in between 30 0 to 60 0 .

They were also found that PDMS can be machined above its glass transition

temperature.Ally et.al [4] observed that the optimum erosion rate occurred at

impact

angles between of 20 0 –30 0 when machining the aluminum 6061-T6,

316Lstainless steel and Ti–6Al–4V alloy and taking the 50 µm AL 2 3

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abrasivepowder. Demonstrating the surface evolution model during the

machiningprocess of metal which was originally developed for ductile polymer

and foundthat AJM etch rate in metal was minimum when compared with the

glass .

polymer.Tyagi [5] has presented a theoretical study carried out with the help

ofmathematical model and computational technique of abrasive jet

machiningwhich is based on the principal of velocity shear instability,

generated by thermionic process. Based upon the plasma factor erosion from

metallic surfacecan be controlled by changing the input parameter such as

electrifield, magneticfield and shear scale length

Lin et.al [6] designed a hybrid model based upon combined mechanismof

abrasive jet machining (AJM) and electrical discharge machining

(EDM).Toremoving the recast layer of SKD 61 steel during the EDM process

indehumidified gas medium the AJM process was incorporated. The

hybridprocess not only increases the material removal rate but also generated

a fine

surface finish.Dehnadfar et.al [7] has finding out the micro machined surface

by applying ajet of particle passed through narrow mask opening in abrasive

jetmicromachining (AJM). The structure of micro machined feature depends

on mass flux and particle velocity. In this experiment shadowgraphy speed

laser technique was used to study the size distributions and particle velocity.

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CHAPTER 3

DESIGN PROCEDURE
3.1 NOZZLE MATERIAL AND DESIGN
Various researchers used different nozzle materials for various applications

and process. Tungsten carbide, sapphire,

HCHCr steel, aluminum nozzles for mixing stage, brass and steel nozzles at

the exit stage, Stainless steel, Tool Steel , deep reactive ion etching (DRIE),

Alloy steel (EN38) heat treated of hardness 50 HRR was used for nozzles are

used as nozzle materials for research purpose.

The abrasive particles are directed into the work surface at high velocity

through nozzles. Therefore, the material of the nozzle is subjected to great

degree of abrasion wear and

hence these are made of hard

materials such as tungsten

carbide or synthetic sapphire.

Tungsten carbide nozzles are

used for circular cross‐sections

in the range of 0.12‐0.8mm

diameter, for rectangular sections of size 0.08 x 0.05 to 0.18 x 3.8 mm and

for square sections of size upto 0.7 mm. Sapphire nozzles are made only for

cross‐sections. The size varies from 0.2 to 0.7 mm diameter. Nozzles are made

with an external taper to minimize secondary effects due to ricocheting of

abrasive particles. Nozzles made of tungsten carbide have an average life of

12 to 30 hours while nozzles of sapphire last for about 300 hour of operation.

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the nozzle is the most critical part in abrasive air-jet machining equipment.

Ceramics, being with high wear resistance, have great potential as abrasive

air-jet nozzle materials. In this paper, a (W,Ti)C/SiC gradient ceramic

composite was developed to be used as nozzle material. The erosion wear

behavior of the (W,Ti)C/SiC gradient nozzle was investigated and compared

with a conventional ceramic nozzle. Results showed that the gradient ceramic

nozzles exhibited an apparent increase in erosion wear resistance over the

conventional ceramic nozzle.

The mechanism responsible was found to be that the tensile stresses at the

entry region of the nozzle were greatly reduced when compared with the

conventional nozzle. This effect may lead to an increase in resistance to

fracture, and thus increase the erosion wear resistance of the gradient

nozzle. It is indicated that gradient structures in ceramic nozzles are effective

to improve the erosion wear resistance of conventional ceramic nozzles in

abrasive air-jet machining Ceramics, being highly wear resistant, have great

potential as abrasive air-jets nozzle materials.

Several studies, have shown that the entry area of a ceramic nozzle exhibits

a brittle fracture-induced removal process, while the center area shows a

plowing type of material removal. As the erosive particles hit the nozzle at high

angles at the nozzle entry section in abrasive air-jet machining, the nozzle

entry region suffers from severe abrasive impact, which may cause large

tensile stresses.

Saurabh Verma et al Abrasive jet (AJM) machining process is non-

conventional machining process. A focused stream of abrasive particles

carried by high pressure air is made to impinge on the work material is

removed by erosion by high velocity Abrasive particles. In abrasive jet

19
machining process abrasive particles like sand (SiO2), glass beads, Aluminum

oxide, silicon carbide is generally used. Two types of

nozzles generally used for average material removal,

tungsten carbide nozzle have a useful life of 12 to 13 hr. and

sapphire nozzles have a useful life of 3hr. Compared with ceramics such as

Si3N4, ZrO2, the strength and fracture toughness of monolithic iC ceramic

material is rather low.

Moreover, the poor sinterability of SiC limits its application because both high

temperature and high pressure are required for a complete densification. In

earlier studies, SiC-based composites have been developed and used in

various applications, mechanical properties and microstructure studies on

them are also extensively carried out. In the present study, the idea of FGMs

was introduced to the design of ceramic nozzle. A (W,Ti)C/SiC ceramic nozzle

with gradient structures was produced by hot-pressing. The purpose is to

reduce

the tensile stress at the entrance area of the nozzle during abrasive air-jet

machin-ing. The erosion wear mechanism of the

(W,Ti)C/SiC gradient nozzles was investigated and compared with that of

conventional ceramics nozzles in abrasive air-jet machining.

The stress along the axial direction of the nozzle decreases from entry to center,

and increases from center to exit. The highest tensile stresses are located at the

entry region of the nozzle. While the wear of the nozzle center area changes

from impact to sliding erosion, the tensile stresses caused by the abrasive

impact in this area are much smaller than those at the entry section. Thus, the

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erosion wear of the nozzle entry region is always serious in contrast with that

of the center area. The most useful is ceramics in modern engineering

applications because of its high hardness, high wear Resistance, high melting

point, good chemical inertness, high Young’s modulus and thermal conductivity

as well as high thermal shock resistance; these attributes make it a promising

candidatefor wear resistance components.

A nozzle to supply the air stream with the abrasive particles The entire polishing

process is performed under the control of a Visual Basic program installed on a

conventional PC. In conducting the polishing process, the variables include the

impact angle of the abrasive jet, the gas pressure, the nozzle-to-work piece

height, the platform rotational velocity, the X–Y platform travel speed, the

additive type, and the mixing ratio of the abrasive material to the additive.In the

present Taguchi design, the machining quality is quantified in terms of the

surface roughness following the polishing operation. The polishing result

obtainedusing the AJP process is governed by six control factors. A.G. Gradeena

et al [10] the resulting abrasive jet temperature was a function of the tubing

length and the air pressure which affected the flow rate. This apparatus was

similar to the low temperature gas blast setup. except that air was used as the

carrier gas rather than nitrogen. In the present setup, the abrasive jet

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temperature could be controlled by changing the length of the heat exchanger,

and the single cooled abrasive jet produced a much more symmetrical

temperature distribution across the blast zone on the target surface.

objective is Precision and repeatable machining using AJM, and operating

problems can arise, including chocking regimes, significant nozzle wear,

contamination of the atmosphere from dispersed fines, as well as continuous

demand for nozzle replacement.

A one-dimensional isentropic flow model was developed to calculate the

particle exit velocity of each individual particle in the airflow for two different

types of nozzles: a converging cylindrical and a new developed line shaped Laval-

type. The simulation shows that the Laval-type nozzle is able to increase the

particle velocity with more than 30% compared to the converging nozzle. Also

the blasting profile is more uniform with a relatively flat bottom.

For bigger round nozzles a decrease in efficiency has been noticed due to the

flux effect. Furthermore, available pressure feeding systems shoceramic nozzle

with gradient structures was prodw lacks through an unsteady particle flow rate.

To overcome these shortcomings of converging and round nozzles, there is a

demands on an improved nozzle design.

The purpose is to reduce the tensile stress at the entry region of the nozzle in

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abrasive air-jet. Results showed that the gradient ceramic nozzles exhibited

anapparent increase in erosion wear esistance over the common ceramic

nozzles.

The mechanism responsible was explained as the formation of compressive

residual stresses in nozzle entry region in fabricating process of the gradient

ceramic nozzles, which may partially counteractthe tensile stresses resulting

from external loadings. A new line-shaped Laval nozzle has been developed,

which is able to increase the particle velocity by 40% compared to a

conventional round nozzle. The blasting-profile of this line-shaped nozzle is

more uniform and the material removal rate is significantly higher compared to

conventional nozzles, which in turn leads to higher achievable aspect ratios of

the three-dimensional microstructures. The traverse speed is most effective

parameter for MRR. Abrasive flow rate is also an important parameter for

increasing MRR. But beyond some limit with increase in abrasive flow rate and

traverse speed the surface roughness decreases.

Increasing traverse speed also increase the kerf geometry and nozzle

wearincreases. So it is required to find optimum condition for process

parameter to give better quality of cutting surface.

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3.2 OPTIMUM PROCESS PARAMETERS
The nozzles are usually made up of Sapphire / Tungsten carbide material of

hardness 50-60 HRC. As the Tungsten carbide material is of high cost, in this

research work, alloy steel (EN38) heat treated of hardness 50 HRC was used for

nozzles. The temperature of air at the exit of nozzle is measured using sensors

(Thermocouples). The optimal combination of process parameters for

simultaneous optimization of MRR and Ra is obtained by the mean values of the

multi-response S/N ratio of the overall utility value.

Observed that there is good agreement between the predicted values and

experimental values of optimization. It can be found that at high temperature,

there is a sufficient evidence of more plastic deformation accompanied by brittle

fracture failure which results in increase of MRR and reduction of roughness.

experiments were performed with a direct pressure type dry abrasive jet

machine mounted on an X:Y table, the specimens being held in a universal type

vice. The nozzle was 2 mm_2 mm in cross-section, 20 mm long and

manufactured from OHNS hardened to 55–60 HRC. A height gauge was used to

establish the necessary jet height. Two series of deburring experiments, each

constructed using a Taguchi experimental design array and two sets of

confirmation experiments were performed, the first series to identify the factors

causing the burr removal and maintaining the edge quality and the second series

24
of experiments to identify the factors influencing the magnitude of the edge

radius generated. The results were verified by a confirmation experiment. Five

independent parameters viz.

SOD, abrasive size, mixing ratio, nozzle pressure and time were varied in the first

experiment of the second series, only SOD being varied in the confirmation

experiment.

Nozzles (WC) are designed and fabricated in different sizes( 1 mm,2mm,3mm)

The abrasive grits (Al2o3, Sic) were mixed with air stream ahead of the nozzle

and the abrasive flow rate was kept constant throughout the machining process.

the Mathematical modeling can be \done in the future work to establish a

mathematical model, which will give a fair idea of the process. a cause and

effect diagram could be drawn to interpret the problems associated with the

effects. central composite design can be used to decide the optimum number

of experiments to be conducted to find out the output. the Response surface

methodology can be used to optimize the process parameters. Contour plots

and response surfaces generated will help to identify the range of parameters

which will maximize or minimize the process parameters. Mathematical

modeling can

25
be done in the future work to establish a mathematical model, which will give a

fair idea of the process. Response surface methodology can be used to optimize

the process parameters.

CHAPTER – 4

RESULT AND DISCUSSIONS

4.1Process capability of abrasive jet machining

• Materials: Hard and brittle material preferred.

• Surface finish: Down to 0.10µm achievable.

26
 • Tolerance: ±0.10mm.

• Feature size: Minimum limit 0.10mm.

• Corner radius: Minimum limit 0.2mm.

• MRR: 15mm3/min.

• Cut thickness: 2 – 6mm plates based on material.

4.2Material removal rate and its estimation

Knowledge of material removal rate (MRR) is beneficial for selecting process

parameters and choosing feed rate of the nozzle. It also facilitates accurate

estimation of productivity, delivery time as well as production cost. Since only

kinetic energy of abrasive grits is utilized for erosion, the analytical formula

for MRR can be established by equating available kinetic energy with the work

done required for creating an indentation of certain cord length on a specific

work material.

However, ductile and brittle materials behave differently in indent formation,

and thus size of indentation created by the impact of single abrasive grit is

27
different for ductile and brittle materials. Under few assumptions, MRR for

abrasive jet machining for different materials can be modeled analytically and

can be expressed as provided below.

The material removal takes place from the work piece by the application high

velocity abrasive jet particle. Due to the kinetic energy of particle causes

erosion of work piece .Thematerial removal is depend upon the certain

parameter such as abrasive flow rate, mixing ratio,gas pressure, stand-off

distance etc. The MRR depends on different process parameter. Material

removal rate (MRR) increases with increase of abrasive flow rate due to the

more number of particle impingement in unit time But after reaching a

optimum value material removal rate decreases with further increase of

abrasive flow rate because of mass flow rate of gas decreases with increase of

abrasive flow rate.

Similarly Material removal rate (MRR) increases with increase of mixing

ratio (M abr /M gas ). But after reaching a optimum value material removal

rate decreases with further increase of mixing ratio.

28
 Material removal rate (MRR) continuously increases with increase in

abrasive flow rate when mixing ratio is kept constant.

Material removal rate (MRR) increases with increase of gas pressure.

At first Material removal (MRR) rate increases with increase in stand-off

distance then it is remains constant for a period of time and after that

decreases with increase in stand –off distance. This phenomena occurs due

to penetration rate of abrasive material is optimum at certain level. After that

it will decreases.

4.3.1Effect of impingement angle on AJM performance

Impingement angle (θ), also called spray angle or impact angle, is basically
the angle between the work surface and abrasive jet axis. Practically it is kept
between 60º – 90º in order to get satisfactory performance in AJ larger angle
tends to create deeper penetration, while smaller angle tends to increase
machining area. An impingement angle (θ) between 70º – 80º provides better
result in terms of material removal rate in abrasive jet machining.

4.3.2Effect of stand-off distance on AJM performance

Distance from the work surface to the tip of nozzle in abrasive jet machining

set-up is called Stand-Off Distance, abbreviated as SOD. Higher SOD causes

spreading of jet and thus its cross-sectional area increases with the sacrifice

of jet velocity. As a consequent, machining deeper slots or hole becomes

difficult; instead a wider area is cut. Alternatively smaller SOD can cut a

deeper but narrow slot or hole. It also enhances MRR. Thus an optimum value

29
of stand-off distance is required to set for obtaining satisfactory performance

in abrasive jet machining.

4.3.3Effects of mixing ratio on AJM performance

Mixing ratio (M) is the ratio between mass flow rate of abrasive particles and

mass flow rate of carrier gas. It basically determines concentration of

abrasives in the jet. Mixing ratio can be increased by increasing abrasive

percentage and in such case an increasing trend in MRR can be noticed

because larger number of abrasives participates in micro-cutting action per

unit time. However, excessive concentration of abrasive in the jet can

significantly reduce MRR because of lower jet velocity (as gas pressure is

constant) and unavoidable collision (thus loss of kinetic energy). MRR can be

enhanced by proportionally increasing both the abrasive flow rate and gas

flow rate at same rate so that mixing ratio remains constant. In such case,

higher pressure of the carrier gas has to be utilized. This necessitates thicker

and stronger pipelines and other accessories to smoothly handle such high

pressure without leakage and rupture. Indefinite increase in MRR is not

practically feasible because of limited capability of equipment and

accessories.

4.3.4Effects of carrier gas on AJM performance

Carrier gas pressure and its flow rate are two paramount factors that

determine performance and machining capability. Higher gas pressure

reduces jet spreading and thus helps in cutting deeper slots accurately.

However, various accessories including pipeline must be capable enough to

handle such high pressure without failure. Moreover, increased gas flow rate

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gives the provision for utilizing higher abrasive flow rate, which can improve

productivity.

4.3.5Effects of abrasives on AJM performance

As discussed earlier, shape, size, strength, material and flow rate of abrasive

can influence machining performance. Irregular shape abrasives having

sharp edges tend to produce higher MRR as compared to spherical grits.

Smaller size grits produce highly finished surface but reduce material removal

rate (MRR) and thus productivity descends. Larger grits can again create

trouble while mixing and flowing through the pipeline. However, variation in

size in the entire volume should be low otherwise estimation or

assessment will not be accurate.

Abrasive materials have varying strength or hardness. The harder is the

abrasive with respect to work surface hardness, the larger will be the volume

removal rate. It is basically the relative hardness between abrasives and

workpiece that determines machining capability and productivity. Mass flow

rate of abrasive is usually controlled by Mixing Ratio, whose effects are also

discussed later in this section.

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CHAPTER – 5

CONCLUSION
All experimental analysis and investigations had done on AJM process.

Qualityof cutting surface in AJM is depending on so many processparameters.

Production is improved by improving the traverse speed but major problem

with increasing traverse speed is that the nozzle wear is started and the flow

of jet is not proper then surface roughness and kerf quality are decreased.

Types of nozzle and nozzle materials affect the efficiency of AJM process.

Abrasive flow rate and types of abrasive also affect the production or MRR.

Efficiency of AJM process is depending on nozzle wear and nozzle wear is

depending on so many process parameter andgeometrical parameters.Process

parameter which affect less or more on quality of cutting AJM are pressure,

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abrasive flow rate, size of abrasive, standoff distance and geometrical

parameter as a nozzle length, nozzle diameter, and nozzle inlet angle, orifice

size. Nozzle wear is measured by % exit bore diameter rate and % volume loss

rate of nozzle and quality of cutting surface is measured by material removal

rate, surface roughness, kerf width, kerf taper ratio. Nozzle failure by erosion

wear is generally caused by fracture owing to the large tensile stress at the

nozzle entry zone Because the nozzle entrance region suffers form severe

abrasive impact, and generates large tensile stress. Thus, the erosion wear of

the nozzle depends on the stress distribution in the entry region. Once the

maximum tensile stress exceeds the ultimate strength of the nozzle material,

frature will occur.

REFERENCES
Book: Advanced Machining Processes by V. K. Jain (Allied Publishers Private

Limited).

Book: Nonconventional Machining by P. K. Mishra (Narosa Publishing House).

R. Balasubramaniam , J. Krishnan, N. Ramakrishnan b,Investigation Of AJM

For Deburring 2007

Deng Jian xin, Wu Feng fang, Zhao Jin Wear mechanisms of gradient ceramic

nozzles in abrasive air-jet machining long February 2007.

Bhaskar Chandra Jagtar Singh , A Study of effect of Process Parameters of

Abrasive jet machining (2011)

33
Bhaskar Chandra Kandpal,Naveen Kumar ,Rahul Kumar, Rahul Sharma,

Sagar Deswal Machining Of Glass And Ceramic With Alumina And Silicon

Carbide In Abrasive Jet Machining (2011)

Book: Nontraditional Manufacturing Processes by G. F. Benedict

(Manufacturing Engineering and Materials Processing-19).

Book: Unconventional Machining Processes by T. Jagadeesha (I. K.

International Publishing House Pvt. Ltd.).

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