ABRASIVE JET MACHINING

AND
STUDY OF PROCESS PARAMETERS

Abrasive Jet Machine

Introduction
Abrasive jet machining (AJM) is a non-traditional machining
process that can machine material without generating heat and
shock.

Abrasive jet machining (AJM) is commonly used for Cutting,

Cleaning, Drilling and Etching operation

Mechanism of AJM
Fine particles are accelerated in
gas stream .
The particles are directed towards
the focus of machining.
As the particle impacts the surface,
it causes a small fracture, and the
gas stream carries both the
abrasive particles and the
fractured (wear) particles away.

Conventional
Abrasive Jet Machine

Compressor

Constructional Details
Equipments involved in the construction of the
Abrasive Jet Machine are as follows

1. COMPRESSOR
2. VIBRATOR
3. MIXING CHAMBER

4. NOZZLE
5. MACHINE TABLE
6. PRESSURE GAUGE & REGULATOR

Process Parameters
The variables that influence the rate of metal removal are as follows :

1.Carrier Gas :

Carbon dioxide, nitrogen & air. Air is most widely used

2.Abrasive :

Aluminum oxide, Silicon carbide, Sodium bicarbonate etc.

3.Velocity of abrasive :
The jet velocity is a function of nozzle pressure & design.
The range of jet velocity is 150-300 m/min

4. Work Material :
It is recommended for processing of brittle material

5. Nozzle Tip Distance (NTD) :

It is the distance between the nozzle tip & work material.

Effect of Process Parameters

on Machining

a) Effect of Pressure of carrier gas on Material Removal Rate (MRR)

S.No.

Gas Pressure
(Kgf/cm2)

Material Removal Rate (MRR)

(mg/min)

18

21

23

26

Table a)1 : Effect of Pressure on MRR

30

20
mg/min

Material Removal Rate (MRR),

25
Gas Pressure Kgf/cm2

15

Material Removal Rate

mg/min

10
5
0
1

Pressure (Kgf/cm2)

Fig a)1 : Effect of Pressure on MRR

Source : Previous Experiments conducted by M. Roopa Rani and S. Seshan

(b) Effect of Nozzle Tip Distance (NTD) on Diameter of Cut.

S. No.

Nozzle Tip Distance

(NTD)
(mm)

Diameter of Cut
(mm)

0.79

0.46

5.00

0.64

10.01

1.5

14.99

2.01

Table b1:Effect of Nozzle Tip Distance on Diameter of Cut.

Fig b1:Shows the effect of Nozzle Tip Distance on Diameter of Cut.

Source : Previous Experiments conducted by M. Roopa Rani and S. Seshan

Block Diagram of
Fabricated Abrasive Jet Machine
Air
Hopper

Compressor

Regulating
Valve

Mixing Chamber

Nozzle

Nozzle Tip Distance

(NTD)
Workpiece
Table

Photograph of
Fabricated Abrasive Jet Machine

Experimental Procedure:
Glass was used as a test specimen, was cut into square and
rectangular shape for machining on AJM.
Specimens were cleaned using air jet and weighed on a sensitive
scale, accurate to 0.001 gram .
Each test sample was placed on the work chamber and machined
by abrasive jet machine by varying various process parameters
The machine work piece was then removed, cleaned and
weighed again to determine the amount of material removed
from the work piece.
The size of hole at the top surface and bottom surface was
measured and the results were tabulated.

Experimental Details:
Experiment No:1- NTD Vs Diameter of Hole
Observation 1.1

1
NTD=6

2
NTD=12

3
NTD=15

4
NTD=18

Fig.1.1.1 Machined Work piece at Pressure = 5.5 kgf/cm 2

Thickness of material = 4 mm

Observation Table
Pressure = 5.5 Kgf/cm2
Top Surface
Dia
(mm)

Bottom Surface
Dia
(mm)

7.05

4.51

12

8.72

5.05

15

11.21

5.33

18

11.65

6.65

Table1.1 Effect of Nozzle Tip Distance on Dia of Hole.

Top Surface Dia.

Bottom Surface Dia.

12
11
10

Dia
Of
Hole
(mm)

NTD (m m)

Graph

S.No.

Nozzle Tip Distance

NTD (mm)

9
8
7
6
5
4
6

10

12

14

16

18

Diameter of hole (mm)

NTD (mm)

Fig 1.1.2. Shows the graph of Diameter of Hole vs. Nozzle Tip Distance

Experiment No:1- NTD Vs Diameter of Hole

Observation 1.2

Fig 1.2.1 Machined Work piece at Pressure =6.5 kgf/cm2

Thickness of material = 4 mm

Observation Table
Pressure = 6.5 Kgf/cm2
S.No.

Nozzle Tip Distance

NTD (mm)

Top Surface Dia

mm

Bottom Surface Dia

mm

7.55

4.55

12

9.75

5.65

15

11.15

5.91

18

11.75

6.05

Table1.2 Effect of Nozzle Tip Distance on Dia of Hole.

Graph
Top Surface Dia.
Bottom Surface Dia.

12
11
10

N TD (m m )

Dia
Of
Hole
(mm)

9
8
7
6
5
4
6

10

12

14

16

18

Diameter of hole (mm)

NTD (mm)

Fig 1.2.2 Graph of Diameter of Hole vs. Nozzle Tip Distance

Experiment No:1- NTD Vs Diameter of Hole

Observation 1.3

Fig 1.3.1 Machined Work piece at Pressure = 8 kgf/cm2

Thickness of material = 4 mm

Observation Table
Pressure = 8 Kgf/cm2
S.No.

Nozzle Tip Distance

NTD (mm)

Top Surface Dia

mm

Bottom Surface Dia

mm

7.72

5.05

12

9.95

5.75

15

11.45

5.96

18

11.81

6.75

Table1.3 Effect of Nozzle Tip Distance on Dia of Hole

Graph

Top Surface Dia.

Bottom Surface Dia.
12
11

Dia
Of
Hole
(mm)

N TD (m m )

10
9
8
7
6
5
6

10

12

14

16

18

Diameter of Hole (mm)

NTD (mm)

Fig1.3.2 Graph of Diameter of Hole vs. Nozzle Tip Distance

Experiment No:2- Pressure Vs Material Removal Rate (MRR)

Observation - 2.1
Fig 2.1.1 Machined work piece for determination of MRR at Pr.=5.5 kgf/cm2
Pressure 5.5 kgf/cm2
Initial weight = 140.190 gm
Final Weight = 140.150 gm
Time = 20 sec
Thickness = 8mm
MRR = 120 mg/min

Fig 2.1.2 Machined work piece for determination of MRR at Pr.=6.5 kgf/cm2
Pressure 6.5 kgf/cm2
Initial weight = 141.200 gm
Final Weight = 141.130 gm
Time = 20 sec
Thickness = 8mm
MRR = 210 mg/min

Fig.2.1.3 Machined work piece for determination of MRR at Pr.=7.5 kgf/cm2

Pressure 7.5 kgf/cm2
Initial weight = 137.530 gm
Final Weight = 137.370 gm
Time = 20 sec
Thickness = 8mm
MRR = 400 mg/min

Observation Table
Thickness = 8 mm, NTD = 12 mm
S.No.

Pressure
kgf/cm2

Initial Weight
(gm)

Final Weight
(gm)

Time
(sec)

MRR
(mg/min)

5.5

140.190

140.150

20

120

6.5

141.200

161.130

20

210

7.5

137.530

137.370

20

400

Table 2.1 Effect of Pressure on MRR

Graph
400

350

MRR (mg/min)

300

250

200

150

100
5.5

6.0

6.5

7.0

7.5

Pressure (Kgf/cm )

Fig.2.1.4 Graph of Pressure vs. MRR

Experiment No:2- Pressure Vs Material Removal Rate (MRR)

Observation - 2.2

Fig. 2.2.1 Machined work piece for determination of MRR at Pr.=5.5 kgf/cm2
Pressure 5.5 kgf/cm2
Initial weight = 206.600gm
Weight = 206.570 gm
Time = 20 sec
Thickness = 12 mm
MRR = 90 mg/min

Fig.2.2.2 Machined work piece for determination of MRR at Pr.=6.5 kgf/cm2

Pressure 6.5 kgf/cm2
Initial weight = 207.130gm
Final Weight = 207.059 gm
Time = 20 sec
Thickness = 12mm
MRR = 213 mg/min

Fig 2.2.3 Machined work piece for determination of MRR at Pr.=7.5 kgf/cm2
Pressure 7.5 kgf/cm2
Initial weight = 201.750 gm
Final Weight = 201.590 gm
Time = 20 sec
Thickness = 12mm
MRR = 480mg/min

Observation Table
Thickness = 12 mm, NTD = 12 mm
S.No.

Pressure
kgf/cm2

Initial Weight
(gm)

Final Weight
(gm)

Time
(sec)

MRR
(mg/min)

5.5

206.600

206.570

20

90

6.5

207.130

207.059

20

213

7.5

201.750

201.590

20

480

Table.2.2 Effect of Pressure on MRR

Graph
550
500

M R R m g /m in

450
400
350
300
250
200
150
100
50
5.5

6.0

6.5

Pressure Kgf/cm

7.0
2

Fig.2.2.4 Graph of Pressure vs. MRR

7.5

Conclusion:
Abrasive Jet Machine was fabricated with following specification:
1.
2.
3.
4.

Diameter of nozzle = 3 mm
Type of abrasive particle aluminum oxide (AlO2)
Pressure range 5 to 8 kgf/cm2
Carrier gas used Dry air

From the experiment conducted it was observed that:

1. As Nozzle Tip Distance increases, the Top surface diameter and Bottom surface
diameter increases
2. As the Pressure increases Material Removal Rate (MRR) also increases.

Scope of Future Work:

In this fabricated abrasive jet unit experiment can be conducted :
1. By using different nozzle tip diameter.
2. By using different type of abrasive particles .
3. By using different sizes of abrasive particles.
4. By using different work material.
5. Also the abrasive jet machine can be improved by retrofitting,
computer numerical control (CNC)

References

M. Roopa Rani and S. Seshan Abrasive Jet Machining-Process Variables and Current
ApplicationMetals Materials and Process,1995 Vol.7 No.4,pp 279-290.

P K Ray and Dr A K Paul, Some Studies on Abrasive Jet Machining Journal of the Institution of
Engineers (India) vol 68 part PE 2 November 1987

Alok K.Verma, Cheng Y. Lin Associate Professor ,Engineering Technology Dept. Old Dominion
University Norfolk, Virginia Parametric Study of the Efficacy of Cutting Process in Abrasive Jet
Machining (AJM)

P. C. Pandey & H.S. Shan , Modern Machining Tata McGraw-Hill Publishing Company , Edition :
1980

Production Technology HMT Tata McGraw-Hill Publishing Company , Edition :1980

Maleev & Hartman Machine Design edited by O. P. Grover CBS Publishing & Distributor

Amitabh Ghosh & Ashok Kumar Malik Manufacturing Process East West Press Private Limited
,New Delhi, Edition 1995

THANKS