Академический Документы
Профессиональный Документы
Культура Документы
1
(Asst. Prof, Mechanical Engineering Department, SRIT College)
2
(Asst. Prof, Mechanical Engineering Department, SRIT College)
3
(Asst. Prof, Mechanical Engineering Department, SRIT College)
ABSTRACT : The objective of the project is to fabricate the abrasive jet machining and study the abrasive jet
machining process by attempting to drill the glass and ceramic work pieces and study the effect of the process parameter
like standoff distance with constant pressure on the material removal rate.
I. INTRODUCTION
Basically, manufacturing processes can be broadly divided into two groups and they are primary manufacturing
processes and secondary manufacturing processes. The former ones provide basic shape and size to the material as per
designers requirement. Casting, forming, powder metallurgy are such processes to name a few. Secondary
manufacturing processes provide the final shape and size with tighter control on dimension, surface characteristics etc.
Material removal processes are mainly the secondary manufacturing processes. Material removal processes once again
can be divided into mainly two groups and they are Conventional Machining Processes and Non-Traditional
Manufacturing Processes. Examples of conventional machining processes are turning, boring, milling, shaping,
broaching, slotting, grinding etc. Similarly, Abrasive Jet Machining (AJM), Ultrasonic Machining (USM), Water Jet and
Abrasive Water Jet Machining (WJM and AWJM), Electro-discharge Machining (EDM) are some of the Non Traditional
Machining (NTM) Processes.
Conventional Machining Processes mostly remove material in the form of chips by applying forces on the work
material with a wedge shaped cutting tool that is harder than the work material under machining condition. Such forces
induce plastic deformation within the work piece leading to shear deformation along the shear plane and chip formation.
In NTM, the tool need not be harder than the work piece material. For example, in EDM, copper is used as the
tool material to machine hardened steels.
1.2 Need for development of Non Conventional Machining
The strength of steel alloys has increased five folds due to continuous R and D effort. In aero-space requirement of High
strength at elevated temperature with light weight led to development and use of hard titanium alloys, nimonic alloys,
and other HSTR alloys. Theultimate tensile strength has been improved by as much as 20 times. Development of cutting
tools which has hardness of 80 to 85 HRC which cannot be machined economically in conventional methods led to
development of non traditional machining methods.
Advance machining process generally classified according o the fundamental energy employed.
Fig 2.1 Schematic working of abrasive jet machining and Crack Propagation in the
Indentation Process
2.2 Performance Parameters
The major variables that influence the rate of metal removal and accuracy of machining in this process are as follows
1. Composition and Density of Gas
2. Type of abrasive
3. Size of abrasive grain
4. Velocity of abrasive jet
5. Flow rate of abrasive jet
6. Work piece material
7. Geometry, composition and material of nozzle.
8. Nozzle tip distance (Standoff distance)
9. Mixing ratio
10. Impingement angle
Sl. No Parameters General values
1 Abrasive material Al2O3 / SiC / glass beads
2 Abrasive shapes irregular / spherical
3 Abrasive size 10-50 m
4 Mass flow rate 2 ~ 20 gm/min
5 Carrier gas Composition Air, CO2, N2
6 Air jet velocity 500 ~ 700 m/s
7 Pressure 2-10 bars
8 Flow rate 5-30lpm
9 Mixing ratio mass flow ratio of abrasive to gas Mabr/Mgas
10 Stand-off distance 0.5 ~ 5 mm
11 Impingement Angle 600 ~ 900
12 Nozzle Material WC / sapphire
Table 2: Performance Parameters standard values
2.3 Operating Characteristics
The main performance measuring parameters of AJM are
1. . The material removal rate in gm/mm3
2. The accuracy and surface finish of the machined surface
3. The nozzle wear rate .
As seen in the graph Fig 2.2 MRR increases with increase in abrasive flow rate due to greater number of particles striking
per unit time. Also MRR increases with increase in mixing ratio which is the ratio of weight of particles to that of the
weight of air. But further increase in mixing ratio decreases MRR due to the fact that the volume of carries gas which is
responsible for the high velocity is reduced. MRR increases with increase in abrasive flow rate when mixing ratio is
constant. The MRR increases with increase in gas pressure as the particles will strike with greater velocity with higher
pressure. Another important parameter is the stand-off distance which is the distance between the nozzle tip and work
piece. As seen in the graph MRR first increase with increase in SOD then remains constant for a period of time and then
decrease. This is due to the fact that flaring of jet occurs at a large distance from the nozzle tip. Also the shape of the
cavity becomes less accurate as the nozzle tip distance increases.
Multistage:-For pneumatic tools and jobs that need more pressure (above 120 PSI, generally), multistage compressors
measure up to meet the demand. Multistage compressors have two or more cylinders. After air is compressed in the first
cylinder, it is passed to the second cylinder for more compression, and so forth. They are needed most when more than
one person will be using the same air compressor, and when high demand air tools are in use. Examples: grinders, air
nailers, air sanders, and tire changers.
Permanent Mount:-The best use for mounted air compressors is obvious. Mounted compressors are typically for
permanent shops, for working out of a truck, and for longer-term job sites. Most mounted compressors are electrically
powered, but mounted, gas-powered compressors can be found for trucks and job sites as well. Permanent mount
compressors aren't portable. They tend to be less expensive. Upgrading permanent mount compressors with air filters,
water filters, and in-line lubrication is easier.
Portable:-As expected, the real advantage to portable air compressors is their portability. The good news is that portable
compressors are versatile, and most jobs that need air compression can be handled just fine by fairly-priced, portable
units. There's really no replacement for mobility when you have to have it, and that's where portable compressors shine.
Generally, air, Nitrogen and carbon dioxide gases are used to propel the abrasive particles. These gases 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. An air compressor Gas should be non-toxic, cheap, and 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 operation.
Figure 3.3: Abrasive container and Inlet openings of Abrasive container & Abrasive mixer.
3.4.3 Nozzle
Basically, nozzle is a device which is used to convert the potential energy in kinetic energy. It is a device designed to
control the direction or characteristics of a fluid flow (especially to increase velocity) as it exits (or enters) an enclosed
chamber or pipe. A nozzle is often a pipe or tube of varying cross sectional area and it can be used to direct or modify the
@IJAERD-2017, All rights Reserved 495
International Journal of Advance Engineering and Research Development (IJAERD)
Volume 4, Issue 2, February -2017, e-ISSN: 2348 - 4470, print-ISSN: 2348-6406
flow of a fluid (liquid orgas). Nozzles are frequently used to control the rate of flow, speed, direction, mass, shape, and/or
the pressure of the stream that emerges from them. The nozzle is a device hose cross-sectional area keeps only 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 is being machined. Nozzles can be classified on the basis of their cross-sectional area. They
are:-
Convergent nozzle
Divergent nozzle
Convergent-divergent nozzle.
Divergent nozzle:-Divergent nozzle is a type of nozzle whose cross-sectional area first decreases and then increases.
This type of nozzle is used to decrease the velocity of fluid (either liquid or gas).
Convergent-divergent nozzle:-It is types of nozzles which is used to first increase the velocity and then decrease it as
the cross-sectional area first increases and then decreases.
Convergent nozzle:-The cross-sectional area keeps on decreasing and as a result the velocity keeps on increasing. This
type of nozzles is used to accelerate the velocity of sub sonic fluids. If the nozzle pressure ratio is high enough, then the
flow will reach sonic velocity at the narrowest point. In our project we are using convergent type nozzle because we need
to increase the velocity of the abrasive and air for better machining. We are using the nozzle which is made of brass. The
rate of material removal and the size of machined area are influenced by the distance of the tip nozzle from the work
piece. The abrasive particles from the nozzle follow a parallel path only for a short distance and then the jet of particles
flares resulting in the over sizing of the hole. It is observed that the jet stream is initially in the form of a cylindrical
shape for about 1.6 mm and then it flares into a cone of 7 included angle. The material removal rate initially increases
with increase in the distance of the nozzle from the work piece because of the acceleration of particles leaving nozzle.
This increase is maximum up to a distance about 8 mm and then it steadily drops off because of increase in machining
area for the same amount of abrasive and decrease in velocity of abrasive stream due to drag. Despite their simple design,
abrasive jet nozzles can be troublesome at times. The main drawbacks are short life of expensive parts, clogging of
orifice due to dirt or moisture, wear, miss alignment and damage to the jewel.
Figure3.5: Nozzle holder. Figure 3.6: Brass nozzle of internal diameter 1.5 mm used for machining
3.4.4 Dehumidifier
It is also known as FR system. FR stands for filter regulator which is necessary for filtering the air and regulating the
pressure. The common impurities suspended in the compressed air are dust particles of various sizes, moisture, and oil
particles. Excess moisture present in the pipeline may result in coagulation of particles and jam the nozzle opening. Air
filters have a porous membrane having various pores sizes like 5, 10, or15 ms. They block the particles larger than the
pores.
3.4.6 Distributor
It is a device which is used to distribute air to all other components of the abrasive jet machining. In our abrasive jet
machine we are using the distributor for supplying air into the abrasive mixer. Normally, the air from the compressor
after passing from the de-humidifier enters the distributor. From the distributor the air supply is then transferred to air
and abrasive mixer and the abrasive container. The air supply is regulated by valves which are controlled manually.
There are four opening in the distributor in which there is a pressure indicator which is used to measure the pressure
entering the distributor from the de-humidifier.the second is the input opening from which the air enters the distributor.
The third opening is for supplying air into the abrasive container to insure the supply of abrasive into the abrasive mixer
which is regulated manually with the help of a valve. i.e. we can control the amount of air supplied in the abrasive
container. The fourth opening ensures the supply of air into the abrasive mixer. The single air supply is then further
divided into supply of air into the abrasive mixer from three directions with the help of pipe distributor.
Figure.3.8: Distributor
3.4.7 Hopper
Hopper is a device which is used to change the potential energy of air and abrasive into the kinetic energy before entering
into the nozzle. Normally, the hopper is of the tapered size. The standard angle of the tapering is done at 45 0. In our
abrasive jet machine we have kept the angle of the hopper at 300. This is used as it slightly changes the velocity of the
abrasive and air i.e. it increases the velocity of the abrasive and air and reduces the potential energy of the abrasive and
air .The velocity is further increased through the nozzle.
Figure.3.9: Hopper.
@IJAERD-2017, All rights Reserved 497
International Journal of Advance Engineering and Research Development (IJAERD)
Volume 4, Issue 2, February -2017, e-ISSN: 2348 - 4470, print-ISSN: 2348-6406
3.4.8Piping system
The piping systems are required for carrying the compressed air from the compressor to the mixing chamber and from the
mixing chamber to the nozzle orifice via the filter regulator. It is required to maintain the pressure in the line without
eroding the pipe. Here, nylon braided hoses having 8mm internal dia. is provided. This is used because of long life, light
weight, durability and easy availability. Also the head loss is very small when it occurs a bend. The hose is composed of
reinforcement of synthetic yarn in between two or more layers of soft PVC. The yarn is reinforced in longitudinal
directions as well as crosswise so as to increase the strength.
Raise the pressure of the compressor up to 5 kg/cm2 in the air receiver of the compressor having automatic
pressure control setting.
The air from the compressor is then passed through the dehumidifier. The dehumidifier then separates the air
from which particles. This is done in order to avoid the clogging of abrasive in the nozzle due to which content
as it may lead to sticking of the abrasive particles to the nozzle surface.
The abrasive container is then filled with the abrasive particles of 40 micron. Screw the cap of the container
tightly to avoid any air leakage.
Check all the joints for air leakage. Now slowly open the valve to supply air from the distributor into the
abrasive container.
Open the valve at the abrasive container to allow the abrasive particles into the mixing chamber and also open
the valve at the distributor to allow the air to enter the mixing chamber from three directions. Keep checking all
the joints to avoid any leakage.
At high pressure abrasive jet is formed at the tip of the nozzle which is ready for machining.
The nozzle tip machining or standoff distance which is the distance of nozzle tip to the work piece is fixed to 10
mm and the corresponding times to cut a glass piece of given dimensions have been recorded. Material removal
rate is calculated by taking out the difference in weight of the work piece before and after machining.
The pressure is maintained constant. And the variables here are time and different work pieces and standoff
distance.
Material removal rate increases as duration of machining increases for both glass and ceramic tile
Material removal rate depends upon the hardness of work piece material as we observed the material removal
rate in glass is more than the ceramic tile for same duration of machining.
@IJAERD-2017, All rights Reserved 498
International Journal of Advance Engineering and Research Development (IJAERD)
Volume 4, Issue 2, February -2017, e-ISSN: 2348 - 4470, print-ISSN: 2348-6406
REFERENCES
[1] Introduction to Nontraditional machining, Jagadeesha T, Assistant Professor , MED, National Institute of
Technology, Calicut.
[2] Drilling of Glass Sheets by Abrasive Jet Machining, by A. El-Domiaty, H. M. Abd El-Hafez, and M. A. Shaker,
World Academy of Science, Engineering and Technology Vol:3 2009-08-29 .
[3] Micro-grooving of glass using micro-abrasive jet machining Dong-Sam Park a, , Myeong-Woo Cho, Honghee Lee ,
Won-Seung Cho, Journal of Materials Processing Technology 146 (2004) 234240
[4] Modern machining process, S Pandey and H N Shah, S. Chand and co.
[5] Elements of workshop technology, S K Hajra Choudhury, S K Bose, A K Hajra choudhury, Niranjan Roy, VolII,
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