Abrasive Jet and Abrasive Flow Machining

By

Muhammad Usman Sarwar

Student of Mechanical Engineering at
Pakistan Institute of Engineering and
Applied Sciences (PIEAS)
 

Report submitted to Mr.Ammar at PIEAS in partial fulfillment of Term Project for

the Degree of BS Mechanical Engineering

Department of Mechanical Engineering

Pakistan Institute of Engineering & Applied Sciences,
Nilore, Islamabad, Pakistan.
Department of Mechanical Engineering,
Pakistan Institute of Engineering and Applied Sciences
(PIEAS) Nilore, Islamabad 45650, Pakistan
 Declaration of Originality
I hereby pronounce that the work contained in this report and the scholarly substance of this
report are the result of my own work. This report has not been already published in any shape
nor does it contain any verbatim of the published assets which could be treated as encroachment
of the global copyright law.
I likewise announce that I do comprehend the terms 'copyright' and 'plagiarism,' and that in the
event of any copyright infringement or literary theft found in this work, I will be considered
completely dependable of the results of any such infringement.

Signature: ______________________________

Name: Muhammad Usman Sarwar

Date: March 12, 2020

Place: PIEAS Nilore, Islamabad, Pakistan.

 Dedication

This report is dedicated to those who make my life worth living and my family members who are
always standing with me no matter how much hard the life becomes for me. This work is
dedicated to my best friends Hassan Ali, Mubashir Usman Ijaz, Muhammad Athar Hassan,
Ameer Hamza Arif, Fahad, Shamshir Ali Raza, Mehtab Jahan and Shahid Ahmed
.
Muhammad Usman Sarwar
 Acknowledgments

I want to acknowledge the efforts of Mubashir Usman and Hassan Ali whose upper hand
knowledge about computers have always helped me throughout my engineering career including
this report.

Muhammad Usman Sarwar

 Table of content

Abrasive Jet and Abrasive Flow Machining.....................................................................................i

1 List of Figures..........................................................................................................................7
2 Introduction..............................................................................................................................9
2.1 Abrasive Jet Machining....................................................................................................9
2.2 Abrasive Flow Machining...............................................................................................10
3 Working.................................................................................................................................10
3.1 Abrasive jet machining...................................................................................................10
3.1.1 Abrasive Used..........................................................................................................11
3.1.2 Carrier Gas Used......................................................................................................12
3.1.3 Nozzle Used.............................................................................................................12
3.2 Abrasive Flow Machining...............................................................................................13
4 Applications...........................................................................................................................15
4.1 Abrasive Jet Machining..................................................................................................15
4.1.1 Work surface cleaning.............................................................................................15
4.1.2 Deflashing and cutting.............................................................................................15
4.1.3 Etching.....................................................................................................................15
4.1.4 Clay scraping and glass icing..................................................................................15
4.1.5 Deburring.................................................................................................................15
4.1.6 Cutting and penetrating opening..............................................................................16
4.2 Abrasive Flow Machining...............................................................................................16
 Radiusing........................................................................................................................16
 Surface Stress Relief.......................................................................................................16
 Cleaning:.........................................................................................................................16
 Geometry Optimization:.................................................................................................16
 Deburring:.......................................................................................................................16
5 Results and Discussion..........................................................................................................17
6 Conclusion.............................................................................................................................17
7 References..............................................................................................................................19
1 List of Figures
Figure 1 AJM...................................................................................................................................9
Figure 2 Working process of AJM................................................................................................11
Figure 3 AFM working..................................................................................................................14
 Abstract
In this report abrasive jet machining and abrasive flow machining which both are non-
conventional machining process are discussed separately in detail.
Firstly, both AJM and AFM are introduced with very minor details. Then there is detailed
working process of both AJM and AFM. Both have abrasives as main component and both have
different abrasives are used differently to shape the material according to our desire.
Then, there are the applications of both AJM and AFM. Both of them have vast field of
applications. AJM and AFM have applications in different spheres according to the its working
and its efficiency.
Lastly, all above is summarized and concluded. Both AJM and AFM are effective material
process having vast applications in industry.
2 Introduction
2.1 Abrasive Jet Machining
It is the material removal process by high velocity gas stream containing abrasive particles.
Abrasive jet machining is the process whereby high-pressure gas or air on the work surface impi
nges the highspeed stream of abrasive particles through a nozzle and metal removal occurs due t
o corrosion caused by highspeed abrasive particles. Owing to frequent impacts, small bits of mat
erial get loosened which is carried away by jet and the fresh surface is expos-ed to the jet.
Abrasive jet machining (AJM) is one of the advanced (mechanical energy-based) machining proc
esses where a highspeed jet of abrasives is used to extract material from the work surface by imp
act erosion. The abrasive jet is obtained in highly pressurized gas (carrier gas) by accelerating fin
e abrasive particles.
The gas must be dry and pressure is generally between 0.2 to 1.4 Mpa. This pressure is used to
propel the dry gas through nozzle orifice of diameter between 0.075 to 1 mm at velocities of 2.5
to 5.0 m/s (500 to 1000 ft/min). Gases include dry air, nitrogen, carbon dioxide, and helium. The
below figure shows the process which will be further elaborated later.[ CITATION GFB \l
1033 ]

Figure 1 AJM

2.2 Abrasive Flow Machining

Abrasive flow machining (AFM), also known as abrasive flow deburring or extrude
honing, is an interior surface finishing process characterized by the flow through a workpiece of
an abrasive-laden fluid. Usually this fluid is very viscous and has the consistency of putty, or
flour. AFM smoothes and finishes rough surfaces, primarily for removing burrs, polishing
surfaces, shaping radii, and even removing material. AFM 's design makes it suitable for interior
surfaces, openings, holes, cavities, and other areas which may be difficult to reach with other
processes of polishing or grinding. The AFM process utilizes an abrasive media applied at high
pressure to change the surface characteristics of the machined component.[ CITATION Ben \l
1033 ]

3 Working
3.1 Abrasive jet machining
Dry air or gas is filtered and compressed by passing through the compressor and filter. To contro
l the pressure and regulate the flow rate of the compressed air, a pressure gauge and a flow regul
ator are used. Compressed air is then passed into the mixing chamber. The abrasive powder is fe
d in the mixing chamber. The abrasive powder feed is regulated through a vibrator.
The grating powder and the compacted air are completely blended in the chamber. The weight of
this blend is managed and sent to nozzle.[ CITATION TJa \l 1033 ]
The abrasive powder and the compacted air are completely blended in the chamber. The weight
of this blend is regulated. Abrasive jet machining (AJM) is one of the progressed machining
forms (mechanical vitality based) where a high speed jet of abrasives is used to expel material
from work surface by sway disintegration. The abrasive jet is gotten by quickening fine abrasive
particles in profoundly pressurized gas (transporter gas). A spout is utilized to change over this
weight vitality into dynamic vitality and furthermore to coordinate the jet towards work surface
at a specific point (impingement edge). Upon sway, hard abrasive particles step by step evacuate
material by disintegration and at some point helped by weak break. what's more, sent to nozzle.
Below figureshows the working process.

Figure 2 Working process of AJM

3.1.1 Abrasive Used

In AJM, hard abrasive particles are assumed to be involved in material removal action, while
carrier gas assists in blowing away eroded particles from the machining zone. Among the ideal
properties adequate hardness, sporadic shape, nearness of sharp edges and great stream attributes
are basic.
Various abrasives having a scope of coarseness size can be used dependent on workpiece
material and the activity it is planned to perform. Aluminum oxide (alumina) of normal
coarseness size 10 – 50µm is ordinarily utilized for cutting and boring activity, particularly when
work material is hard. Notwithstanding, for exceptionally difficult work material, silicon carbide
(SiC) is favored as it is more earnestly than alumina. For cleaning and covering expulsion
purposes, glass globules and smashed glass are expectedly utilized. Size of abrasives impacts
nature of cut just as material evacuation rate. Bigger coarseness size will in general produce
bigger depression and hence MRR improves with the penance of surface completion. Then
again, fine abrasives lessen MRR however improve surface quality and exactness.[ CITATION
Ahm00 \l 1033 ]

3.1.2 Carrier Gas Used

The basic aim of carrier gas in abrasive jet machining is to speed up fine abrasive particles (by
transmission of momentum). A compressor is used to raise the carrier gas pressure (up to 20bar);
abrasive grits are combined with it in a mixing chamber (as per mixing ratio) and a nozzle is
used to transform the energy of pressure into kinetic energy (in the form of a high speed jet).
Carrier gas pressure alongside spout distance across decides last jet speed and in this manner
machining execution. Among different gases, air is generally utilized in AJM as it is liberally
accessible at liberated from cost. At some point monetarily unadulterated carbon di-oxide and
nitrogen are additionally used to bridle better execution for a specific reason. Be that as it may,
unadulterated oxygen isn't utilized as it can rapidly oxidize the work surface. Prior to packing,
transporter gas is dehumidified appropriately as nearness of steam can square pipelines. At the
point when gas is packed to high weight, steam may consolidate and little water particles can
make a bigger globule in the wake of agglomerating with abrasives. Carrier gas is likewise made
residue free before packing to high weight.[ CITATION GFB \l 1033 ]

3.1.3 Nozzle Used

In abrasive jet machining, the primary function of the nozzle is to convert the pressure energy of
the gas-abrasive mixture into kinetic energy in the form of a high-speed jet. Nozzle additionally
coordinates high speed jet towards work surface from a particular separation (called SOD) and at
a specific predefined point, called impingement edge. Internal distance across of the nozzle is
vital boundary as it decides last speed and cross-sectional territory of the jet for specific gas
pressure. As stream rate and blower conveyance pressure are consistent, jet speed will be
conversely corresponding to the jet cross-sectional region.
Picking nozzle material is another definitive factor according to financial perspective. Generally
tungsten carbide (WC) or sapphire nozzles are utilized in mechanical applications. WC nozzles
are less expensive however have restricted life (20–30hr); while sapphire nozzles have
broadened life (150–200hr) yet are costlier. Visit changing of nozzle is related with inert time
during machining.

3.2 Abrasive Flow Machining

The abrasive fluid flows through the workpiece during abrasive flow machining and effectively
performs erosion. Abrasive particles in the interaction with fluids lifted and damaged features on
the workpiece surface. The fluid is pushed through a hydraulic ram[3] into the workpiece, where
it functions as a flexible disk, or slug, molding itself precisely to the workpiece form.
The essential idea of rough stream machining is grating disintegration or metal cutting by high
speed grating molecule. Its working procedure can be handily summed up into following point.
The most noteworthy measure of material evacuation happens in zones where the progression of
the liquid is limited; as per Bernoulli's Principle, the stream speed and weight of the liquid
increment in these regions, encouraging a higher material expulsion rate (MRR). The weight
applied by the liquid on all reaching surfaces additionally brings about an extremely uniform
completion.
AFM might be performed once, as a single direction stream process, or over and over as a two-
way stream process. In the two-way stream process, a store of medium exists at either end of the
workpiece, and the medium streams to and fro through the workpiece from repository to supply.
 First gas or air is compacted into gas blower. There the thickness and weight of gas
increments.
 Presently this compacted gas send to filtration unit, where dust and other suspended
molecule expelled from it.
 This perfect gas sends to drier, which assimilate dampness from it. It is utilized to
maintain a strategic distance from water or oil tainting of grating force.
 Presently this spotless and dry gas sends to blending chamber where grating feeder feed
rough molecule in it. The grating molecule is around 50 miniaturized scale meter
coarseness size.
 This high compelling grating conveyed gas send to spout where its weight vitality
changed over into motor vitality. The speed of grating molecule leaving the spout is
about 200m/s.
 The deadlock separation between work piece and spout is about 2mm.
 Presently these high-speed rough particles encroach on work piece. These high-speed
rough particles expel the material by smaller scale cutting activity just as weak break of
the work material. [ CITATION Ahm00 \l 1033 ]
Below figure presents the working process
 Figure 3 AFM working

4 Applications
4.1 Abrasive Jet Machining
Abrasive jet machining can be used in a range of ways including surface washing, deburring,
abrading and even holes making. Common applications are provided below for the abrasive jet
machining process. It should be noted that abrasive jet machining (AJM) is advantageous for
hard and fragile materials only, regardless of the intent. When work material is soft and ductile,
AJM should be avoided; otherwise, the consistency of the machined surface will be poor.

4.1.1 Work surface cleaning

AJM can be profitably utilized for cleaning metallic or clay surfaces (substrate must be hard).
Such cleaning forms incorporate evacuation of oxide, paint, covering, stain, stick, free sand
particles, and so forth.

4.1.2 Deflashing and cutting

Controlled grating plane machining can be used for evacuating blaze to get wanted clean item
with higher dimensional precision and resistance just as lavish appearance.

4.1.3 Etching
As an option in contrast to laser pillar machining, grating plane machining can likewise be
applied for chiseling purposes regardless of substance and electrical properties of work material.
4.1.4 Clay scraping and glass icing
Very hard materials including glass, headstrong, stone, and so forth can be handily rubbed by
AJM so as to get completed surface having tight resilience.

4.1.5 Deburring
Abrasive stream machining is one of the effective techniques for deburring (process for
evacuation of burr) of processed highlights and penetrated openings, particularly when work
material is hard.

4.1.6 Cutting and penetrating opening

AJM can likewise be used for cutting different shapes just as for boring gaps. In any case,
openings, spaces or pockets may need precision as sharp corners can't be acquired by this
procedure.[ CITATION GFB \l 1033 ]

4.2 Abrasive Flow Machining

The AFM procedure gives top notch results to machined segments that require the evacuation of
flaws made by mechanical procedures. This makes AFM perfect for the accompanying surface
machining applications:

 Rai-using: Generating nonstop obvious edge or adjusted edge radii.

 Surface Stress Relief: Smoothing out segment basic weariness focuses and
evacuating pressure risers that may prompt split spread.

 Cleaning: Uniformly improving the surface completion while saving the part geometry.
 Geometry Optimization: Improving passage and leave gaps and adjusting surfaces
to improve the stream qualities of the completed part.

 Deburring: Removal of material appended to a part because of drilling, penetrating or

cutting activities.
5 Results and Discussion
Both AJM and AFM are discussed above, First both are introduced then detailed working
process of both is discussed followed by the applications.
Abrasive jet machining (AJM) is one of the advanced machining processes (mechanical energy
based) where a high velocity jet of abrasives is utilized to remove material from work surface by
impact erosion. The abrasive jet is obtained by accelerating fine abrasive particles in highly
pressurized gas (carrier gas). 
AJM is 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 materials
There is low capital investment
Abrasive flow machining (AFM) is also known as Extrude honing. This is an interior surface
finishing method that includes pushing an abrasive-laden fluid through the chamber to be
cleaned.
AFM is low metal removal rate process. Abrasive particle can embedded into work piece mostly
in soft metals. Nozzle life is limited so it needs frequently replacement. Abrasive particle cannot
be reuse in this process. It cannot use for machine soft and ductile material.

6 Conclusion
Both abrasive jet machining and abrasive flow machining use different type abrasives in their
working process.
Both of them have different procedures but abrasive is main component of both of them.
Abrasive jet machining principle, working, equipment’s, application, advantages and
disadvantages with its diagram. Abrasive jet machining is a non-traditional machining process
which is mostly used in machining of hardened metals.
AFM is an interior surface finishing process that involves an abrasive-laden fluid being forced
through the chamber that needs to be cleaned. The fluid is typically viscous with the consistency
of putty, which gives it the ability to smooth and finish the interior surfaces that one would
otherwise be unable to reach. This process is specially used to polish rough surfaces, remove
burrs, and even increase the size of a chamber.
7 References

[1] G. F. Benedict, Nontraditional Manufacturing Processes.

[2] G. F. Benedict, Nontraditional Manufacturing Processes.
[3] T. Jagadeesha, Unconventional Machining Processes, I. K. International Publishing House
Pvt. Ltd.
[4] A. K. and L. E. Doyle, Manufacturing processes and materials, 2000.