e-ISSN (O): 2348-4470

Scientific Journal of Impact Factor (SJIF): 4.72

p-ISSN (P): 2348-6406

International Journal of Advance Engineering and Research

Development
Volume 4, Issue 2, February -2017

Fabrication of Abrasive Jet Machine

N Vikram Manoj Kumar 1, K Neelakanta2 V Arundhati3

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.

KEYWORDS -Fabrication, Abrasive, Non conventional Machining,

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.

1. 1 Classification of conventional machining processes with non-conventional 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.

Figure1.1: Shear deformation in conventional machining process leading cheap deformation.

The major characteristics of conventional machining are:
Generally, macroscopic chip formation by shear deformation
Cutting tool is harder than work piece at room temperature as well as under machining conditions.
Non Traditional Machining (NTM) Processes on the other hand are characterized as follows:
Material removal may occur with chip formation or even no chip formation may take place.
In NTM, there may not be a physical tool present.
@IJAERD-2017, All rights Reserved 490
 International Journal of Advance Engineering and Research Development (IJAERD)
Volume 4, Issue 2, February -2017, e-ISSN: 2348 - 4470, print-ISSN: 2348-6406

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.

1.3 Classification of Advanced Machining Process

Advance machining process generally classified according o the fundamental energy employed.

Fig 1 Classification of Advanced Machining Process

II. MECHANISM OF METAL REMOVAL PROCESS AND PROCESS PARAMETERS

2.1 Mechanism of Metal Removal

The Abrasive Jet Machining (AJM) is considered as an attractive effective machining method for hard and brittle
materials.AJM is different from standard shot or sand blasting, as in AJM, finer abrasive grits are used and the
parameters can be controlled more effectively providing better control over product quality. Abrasive Jet Machining
(AJM), abrasive particles are made to impinge on the work material at a high velocity. The jet of abrasive particles is
carried by carrier gas or air. The high velocity stream of abrasive is generated by converting the pressure energy of the
carrier gas or air to its kinetic energy and hence high velocity jet. The nozzle directs the abrasive jet in a controlled
manner onto the work material, so that the distance between the nozzle and the work piece and the impingement angle
can be set desirably. The high velocity abrasive particles remove the material by micro-cutting action as well as brittle
fracture of the work material.
In AJM, generally, the abrasive particles of around 50 m grit size would impinge on the work material at velocity of 200
m/s from a nozzle of I.D. of 0.5 mm with a standoff distance of around 2 mm. The kinetic energy of the abrasive particles
would be sufficient to provide material removal due to brittle fracture of the work piece or even micro cutting by the
abrasives.
According to the machining model proposed by Slikkerveer when a sharp indenter tip moves down to the inside of the
work piece, a plastic deformation zone is formed under the indenter tip due to the compressive force. The formed plastic
zone becomes larger as the compressive force increases. Eventually, radial/median and lateral cracks are formed along
the perpendicular and parallel direction of the surface, respectively. At this time, it can be assumed that the lateral cracks
have relationships with the work piece removal process in AJM, and the radial/ median cracks have relationships with the
surface crack formation. It plays a key role in accelerating the removal process at some level as the machined depth is
increased. Figure 2.1 shows the crack formation in the indentation process.
@IJAERD-2017, All rights Reserved 491
 International Journal of Advance Engineering and Research Development (IJAERD)
Volume 4, Issue 2, February -2017, e-ISSN: 2348 - 4470, print-ISSN: 2348-6406

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

@IJAERD-2017, All rights Reserved 492

 International Journal of Advance Engineering and Research Development (IJAERD)
Volume 4, Issue 2, February -2017, e-ISSN: 2348 - 4470, print-ISSN: 2348-6406

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.

Figure 2.2: Operating Characteristics.

2.4 Advantages of Abrasive jet Machining.
1. Ability to cut intricate holes shape in materials of any hardness and brittleness.
2. Ability to cut fragile and heat sensitive material without damage.
3. No change in microstructure as no heat is generated in the process.

2.5 Applications of Abrasive jet Machining

There are various applications of abrasive jet machining. Some of them are:
1. For drilling holes of intricate shapes in hard and brittle materials
2. For machining fragile, brittle and heat sensitive materials
3. AJM can be used for drilling, cutting, cleaning and etching.
4. Micro-machining of brittle materials.

2.6 Limitation of Abrasive jet Machining

1. Material removal rate is very low.
2. The abrasive particles tend to get embedded with the work piece if the work piece is a ductile metal.
3. The abrasive material may accumulate at nozzle and fail the process if
the moisture is present in the air.
4. It cannot be used to drill blind holes.
5. Tapering occurs due to flaring of the jet
6.
III. EXPERIMENTAL SETUP
3.1 Introduction
The abrasive jet machine comprises of many elements. They are nozzle, abrasive mixer, pressure control valve, filter,
dehumidifier, electromagnetic shaker, air compressor, and abrasive feeder. The air is first compressed in the air
compressor near about 5 bar. Gases like CO2, N2 can also be used as a carrier gas which may directly be issued from a
gas cylinder. Generally oxygen is not used as a carrier gas. The gas is first passed through a pressure regulator to obtain
the desired working pressure. The gas is then passed to a series of air filters to remove any impurities such as oil from it,
moreover it is then passed through a drier to remove any water particles present in the air. Then the carrier gas enters a
closed chamber known as mixing chamber. The abrasive particle then enters the mixing chamber through the hopper
from a metallic sieve. The carrier gas then carries the abrasive particles to the working chamber. The machining
enclosure is necessary for containing the abrasive and machined particles in a safe and eco friendly manner. The
machining is carried at a velocity more than 200m/sec and the abrasive is issued from the nozzle on the work piece.

@IJAERD-2017, All rights Reserved 493

 International Journal of Advance Engineering and Research Development (IJAERD)
Volume 4, Issue 2, February -2017, e-ISSN: 2348 - 4470, print-ISSN: 2348-6406

Figure3.1: Layout of abrasive jet machine.

3.2 Design Methodology

An abrasive machine was fabricated in the institute workshop with required raw materials and procured components.
Before that a detailed design of the functional subsystems were made .The components that were designed include the
machining chamber, work-holding device, nozzle and its holder, abrasive container and total piping system. Care was
taken so to optimally use the material and space in the production engineering lab along with ease in using. The final
components were fabricated in the workshop using the available materials like mild steel sheets bars and pipes,
Aluminum sheets, rubber sheets, glass fiber, standard nuts and bolts etc. For fabrication purpose the welding machine,
grinding machine, the hand-drill, sheet-bending machine, and shearing machines were used. Some components are
procured from commercial market to improve accuracy.

3.3 Machining Chamber

3.3.1 Air tight chamber
The abrasive particles used in AJM are of very fine grit size and can be remain suspended in the air for very long time.
Normally it is injurious to health if inhaled. So proper care has to be taken to prevent it from mixing with the atmosphere
and dispose it. For this purpose the chamber was made air tight by application of suitable methodology. Mild steel sheet
of 1 mm thickness was taken and was converted into a one side open box with bending, shearing, cutting and welding
operations. Mild steel sheet was chosen as it has excellent formability along with weld ability.
3.3.2 Work holding device
In the AJM machining process the most common work pieces are glass sheets, glass fiber sheets, ceramic slabs etc. due
to their brittleness. Material removal rate is lesser in ductile material due to the fact that ductile materials try to get
embedded in the work material.
3.3.3 Opening & Closing system
For opening and closing of the chamber sliding movement was provided for simplicity. The front panel of glass fiber can
be opened by this method. The hinges were of mild steel material and light weight in nature. They were secured to the
mild steel box by nuts and bolts. As there is a chance of leakage of air + abrasives through the gap between the metal and
glass fiber a rubber strip was provided on the plate periphery.

3.4Components of Abrasive jet Machining

The abrasive jet machining consists of a number of components. They are gas propulsion system, abrasive feeder, mixing
chamber, nozzle, working chamber which are explained below.
3.4.1 Gas Propulsion system
Gas propulsion system supplies clean and dry air. An air 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, which, on
command, can be released in quick bursts. Generally, air compressors are classified as:
Single stage compressors
Multi-stage compressors
Portable compressors
Non-portable compressors
Single stage:-The "single" in "single stage" means that they only have one cylinder for compressing air. For most air tool
jobs, especially jobs around the house, single stage air compressors perform nicely.

@IJAERD-2017, All rights Reserved 494

 International Journal of Advance Engineering and Research Development (IJAERD)
Volume 4, Issue 2, February -2017, e-ISSN: 2348 - 4470, print-ISSN: 2348-6406

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.

Figure3. 2: Two Stage reciprocating compression pump

3.4.2 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.

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.

Figure 3.7: Dehumidifier.

@IJAERD-2017, All rights Reserved 496
 International Journal of Advance Engineering and Research Development (IJAERD)
Volume 4, Issue 2, February -2017, e-ISSN: 2348 - 4470, print-ISSN: 2348-6406

3.4.5 Pressure Regulator

A pressure regulator has a restricting element, a loading element, and a measuring element. The restricting element is a
type of valve. It can be a butterfly, valve globe valve, poppet valve, or any other type of valve that is capable of operating
as a variable restriction to the flow. The loading element applies force to the restricting element. It can be a simple
weight, a spring, a piston actuator, a diaphragm actuator in combination with a spring. Here a single-stage pressure
regulator, a force balance is used on the diaphragm to control a spool in order to regulate pressure. With no inlet pressure,
the spring above the diaphragm pushes it down on the spool, holding it open. When inlet pressure is introduced, the open
spool allows flow to the diaphragm and pressure in the upper chamber increases until the diaphragm is pushed upward
against the spring force, causing the valve to reduce flow, thus stopping further increase of pressure. By adjusting the top
screw by rotation, the downward pressure on the diaphragm can be enhanced, requiring more pressure in the upper
chamber to maintain equilibrium. In this way, the output pressure of the regulator is controlled within a safe limit

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.

Figure 3.11: Complete Experimental Setup of Abrasive jet machine

IV. RESULTS AND DISCUSSION

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.

V. Conclusion And Future Work

5.1 Conclusion
In this project we attempted to fabricate Abrasive jet machine and performed experiments on glass and ceramic tile at
constant pressure of 4 kgf/cm2, constant standoff distance 10 mm for duration of 2 minute, 3 minute and 4 minute using
1.5 mm diameter nozzle using alumni oxide as abrasive material. On performing experiments we found

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

5.2 Future work

A more detailed study can be done
By changing the pressure and stand-off distance and its effect on material removal rate.
The wear rate of nozzle can be studied.
How does different abrasive and different grain size can affect the MRR
Development of automated work holding device

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,
Media promoters and media publications

@IJAERD-2017, All rights Reserved 499