GREATER NOIDA INSTITUTE OF TECHNOLOGY

PLOT NO.7,K.P.II, GREATER NOIDA

Affliated to Uttar Pradesh Technical University, Lucknow

CERTIFICATE

This is to certify that project report entitled "Design And Fabrication of portable Experimental
Set-up For Abrasive Jet Machining Process " which is submitted by Arun Kumar, Anand
Prakash, Arun sharma and Akshay katyar in partial fulfillment of the requirement for the award
of degree B.Tech in Department of Mechanical Engineering of Greater Noida Institute of
Technology, affiliated to Uttar Pradesh Technical University, is a record of the candidates own
work carried out by them under my supervision. The matter embodied in this thesis is original
and has not been submitted for the award of any other degree.

(Mr.Anuj Dixit)

(Mr.SUDHIR KUMAR)

(CO-ORDINATOR)

(H.O.D)

DATE:

DATE:

ACKNOWLEDGEMENT

Every project big or small is successful largely due to the effort of a number of wonderful people
who have always given their valuable advice or lent a helping hand. I sincerely appreciate the
inspiration; support and guidance of all those people who have been instrumental in making this
project a success.
We, the student of GNIOT, Greater Noida (Mechanical), am extremely grateful and Extend my
gratitude to my Project Guide Mr.Anuj Dixit , who assisted me in compiling the project. For
making the resources available at right time and providing valuable insights leading to the
successful completion of my project.
I would also like to thank all the faculty members of GNIOT, Greater Noida for their critical
advice and guidance without which this project would not have been possible. Last but not the
least I place a deep sense of gratitude to my family members and my friends who have been
constant source of inspiration during the preparation of this project work.

Signature:
Name: Arun Sharma
Roll No: 1213240039

Signature:
Name: Akshay Katihar
Roll No: 1213240013

Signature:
Name: Arun Kumar
Roll No: 1213240040

Signature:
Name: Anand Prakash
Roll No: 1213240022

Date:

ABSTRACT

Abrasive jet machining is the non-traditional material removal process. It is an effective

machining process for processing a variety of Hard and Brittle Material. And has various distinct
advantages over the other non-traditional cutting technologies, such as, high machining
versatility, minimum stresses on the work piece, high flexibility no thermal distortion, and small
cutting forces. . The objective of AJM is to get high MRR. The machining parameters that
achieve the highest MRR strongly depend on the size of the work piece, pressure and NTD
In this AJM machine we have used a mixing chamber which regulates the mixture and a FR unit
which is used as Filtering and Regulating Unit of the air pressure which comes out from the
chamber. Lime Glass has been used as a work piece in this experiment which has given the
different MRR according to the variable parameters which we have taken in this experiment. The
optimal set of parameters has also been predicted to maximise the metal removal rate. For the
conduction of experiments L9 orthogonal array was used to complete the runs based on the
Taguchi method with input factors Discharge current, Pulse on Time, Pulse off Time and
Flushing pressure. The Signal-to-Noise (S/N) ratios and means associated with the observed
values were plotted and the factor effecting the micro-hardness of the work-piece has been
obtained.

DECLARATION
We hereby declare that this submission is our own work and that, to the best of my
knowledge and belief, it contains no materials previously published or written by
another person nor material which to a substantial extent has been accepted for the
award of any other degree or diploma of the university or other institute of higher
learning, except where due acknowledgment has been made in the text.

Signature:
Name: Arun Sharma
Roll No.:1213240041
Signature:
Name: Akshay Kathiar
Roll No.:1213240015
Signature:
Name: Arun Kumar
Roll No.:1213240040
Signature:
Name: Anand Prakash
Roll No.:1213240022
Date:

Contents

Topic
Page No.
Certificate --------------------------------------------------------------- i
Acknowledgement ----------------------------------------------------- ii
Abstract------------------------------------------------------------------ iii
Declaration-------------------------------------------------------------- iv
Contents ----------------------------------------------------------------- v
List of Figure ----------------------------------------------------------- viii
List of Tables ----------------------------------------------------------- ix
Nomenclature ----------------------------------------------------------- x
CHAPTER 1 INTRODUCTION-----------------------------------------1
1.1 Introduction to Non-Traditional Machining process---------------1
1.2 Abrasive Jet machining ------------------------------------------------2
1.3 Application of AJM-----------------------------------------------------3
CHAPTER 2 LITERATURE REVIEW-------------------------------4
2.1Research paper by previous scientist ---------------------------------4
2.2Gap in literature review-------------------------------------------------7
CHAPTER 3 THEORITICAL BACKGROUND--------------------8
3.1 AJM Principle------------------------------------------------------------8
3.2 AJM Function------------------------------------------------------------8
3.2.1 Mechanism of Material Removal in AJM ------------------9
3.2.2 Application of AJM--------------------------------------------9
3.2.3 Advantages of AJM--------------------------------------------9
3.2.4 Disadvantages of AJM-----------------------------------------9
3.3 Process Parameters of AJM--------------------------------------------10
3.3.1 Important Parameters of AJM-------------------------------11
3.4 Mechanism of MRR----------------------------------------------------11
3.5 Introduction of Taguchi Method -------------------------------------12
3.5.1 Taguchi Method and Design----------------------------------13
3.5.1.1 The Design Process----------------------------------------13
3.5.1.2 System Design----------------------------------------------14
3.5.1.3 Parameter Design-------------------------------------------14
3.6 Orthogonal Array -------------------------------------------------------14
CHAPTER -4 METHODOLOGY
4.1 Taguchi Experimental Design and Analysis-------------------------16
5

4.2 Experimental Plan ------------------------------------------------------17

4.2.1 Response variable -----------------------------------------------17
4.2.2 Objective Function-----------------------------------------------18
4.2.3 Design Factor-----------------------------------------------------18
4.2.4 Determine the no. of Level and the Level Values -----------19
4.3 Selection of Orthogonal Array-----------------------------------------19
4.4 Conducting the Experiment --------------------------------------------20
4.5 Analyze the data from the Experiment--------------------------------21
4.5.1 Taguchi Design Experiment in Minitab Software ----------22
4.6 Confirmation Experiment ----------------------------------------------23
CHAPTER -5 EXPERIMENTAL SETUP
5.1 Proposed Experimental Setup of AJM--------------------------------25
5.1.1 Equipments -----------------------------------------------------25
5.1.2 Description of Various Parts----------------------------------25
5.1.2.1 Air compressor---------------------------------------------26
5.1.2.2 FR Unit------------------------------------------------------26
5.1.2.3 Mixing Chamber-------------------------------------------27
5.1.2.4 Connecting Pipe -------------------------------------------28
5.1.2.5 Nozzle-------------------------------------------------------28
5.1.2.6 Work Piece--------------------------------------------------28
5.2. Conducting Experiments ----------------------------------------------29
5.2.1 Experimental Procedure ----------------------------------------29
5.3 Calculation of Response Variable ------------------------------------33
5.3.1 Material Removal Rate-----------------------------------------33
CHAPTER-6 RESULTS & DISCUSSION
6.1 Calculated Response Variables---------------------------------------34
6.2 Effects of input factors on MRR--------------------------------------35
6.3 Performance Prediction of MMR-------------------------------------36
6.4 Confirmation Experiments --------------------------------------------38
CHAPTER-7 CONCLUSION
7.1 Findings for MRR-----------------------------------------------------40
References -------------------------------------------------------------41
Appendix----------------------------------------------------------------42

LIST OF FIGURES
NUMBER

TITLE

PAGE No

Figure 4.1

Considered process variable of W/P

18

Figure4.2

Experimental Flow Chart

21

Figure4.3

Methodology Flow Chart

24

Figure5.1

AJM Experimental Setup

25

Figure5.2

Air Compressor

26

Figure5.3

FR Unit

27

Figure5.4

Mixing Chamber

27

Figure5.5

Connecting Pipes

28

Figure 5.6

AJM Machine

30

Figure 5.7

Drilled Work Piece by AJM

36

Figure 6.1

Mean Effects Plot For S/N Ratio

40

LIST OF TABLES
NUMBER

TITLE

PAGE No

Table 3.1

Process Parameters

Table 3.2

Orthogonal Array

Table 4.1

Factors of Process Parameters

Table 4.2

Standards L9 Orthogonal Array

Table 5.1

Design Matrix of Machining Parameters & L9 Orthogonal Array

Table 5.2

Observation Table

Table 5.3

Table for MRR

Table 6.1

Design Matrix with Calculated MRR

Table 6.2

Conversion Table for S/N Ratio for MRR

Table 6.3

Response Table for S/N Ratio

NOMENCLATURE
Symbol

Description

AJM

Abrasive Jet Machine

MRR

Material Removal Rate

NTD

Nozzle Tip Distance

min

Minute

wt

Weight

W/p

Work Piece

S/N

Signal to Noise Ratio

DOF

Degree of Freedom

MS

Mean of Squares

%P

Percentage Contribution

gm

Gram