MAHARASHTRA STATE BOARD OF TECHNICAL

EDUCATION, MUMBAI

SANT GAJANAN MAHARAJ RURAL POLYTECHNIC

MAHAGAON

DEPARTMENT OF MECHANICAL ENGINEERING

ACADEMIC YEAR
2022 – 2023

REPORT ON
‘ABRASIVE JET MACHINING PROCESS’

SUBMITTED BY
MR. BALKRISHN KOKITKAR
GUIDED BY
Prof. A.G.DANGI

MAHARASHTRA STATE BOARD OF TECHNICAL

EDUCATION, MUMBAI
 CERTIFICATE
SANT GAJANAN MAHARAJ RURAL POLYTECHNIC,
MAHAGAON DEPARTMENT OF MECHANICAL
ENGINEERING

This is to certify that the report on

‘ABRASIVE JET MACHINING PROCESS’

SUBMITTED BY
NAME ENROLLMENT NO. ROLL NO.
BALKRISHN KOKITKAR 2009650120 09

Here the award of a Diploma in Mechanical Engineering is the result of the

work completed under my supervision and guidance. This report is submitted as
the fulfillment of the requirement Diploma course prescribed by the
Maharashtra State Board of Technical Education, Mumbai.

Date - / / 2022
Place – Mahagaon

GUIDE NAME HOD NAME PRINCIPAL NAME

Prof A.G.DANGI Prof V.R MOHITE Prof. D.B. KESTI
 DECLARATION
I hereby declare that the report on, ‘ABRASIVE JET MACHINING
PROCESS’submitted to the department of Mechanical Engineering SGMRP,
Mahagaon is based on my work carried out during our study. This report is
prepared under the guidance of our mentor V.R MOHITE. The work done has
not been submitted to any other institution for any other
degree/diploma/certificate in this college or any other university in India. We
have followed all the instructions and guidelines given by the mentor and the as
per mentioned in the syllabus for preparing this report. Whenever we have used
the best resources or materials from other sources, we have given due credit to
them in the text of the report along with their details in the reference section.

Date - / / 2022
Place – Mahagaon
INTRODUCTION:
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). A nozzle is used to convert this pressure energy into kinetic energy and
also to direct the jet towards work surface at a particular angle (impingement
angle). Upon impact, hard abrasive particles gradually remove material by
erosion and sometime assisted by brittle fracture.
AJM differs from age old sand blasting technique by the achievable level of
accuracy and precision. AJM utilizes various abrasives including alumina,
silicon carbide, glass beads, sodium bicarbonate, etc.; whereas sand blasting
predominantly utilizes only silica sand (SiO2). Although purposes of both the
processes are quite similar, cutting parameters can be controlled precisely in
AJM and thus it can provide better accuracy and precision.
Abrasive particles used in abrasive jet machining:

In AJM, it is assumed that hard abrasive particles participate in material

removal action, while carrier gas assists to blow away eroded particles from
machining zone. Such abrasives must possess few basic properties for efficient
removal of material as well as to get desired quality of cut. Among the desired
properties sufficient hardness, irregular shape, presence of sharp edges and good
flow characteristics are essential.
Different abrasives having a range of grit size can be utilized based on
workpiece material and the operation it is intended to perform. Aluminum oxide
(alumina) of average grit size 10 – 50µm is commonly used for grooving and
drilling operation, especially when work material is hard. However, for very
hard work material, silicon carbide (SiC) is preferred as it is harder than
alumina. For polishing and coating removal purposes, glass beads and crashed
glass are conventionally used. Size of abrasives also influences quality of cut as
well as material removal rate. Larger grit size tends to produce larger cavity and
thus MRR improves with the sacrifice of surface finish. On the other hand, fine
abrasives reduce MRR but improve surface quality and accuracy.
Carrier gas for abrasive jet machining:

Basic purpose of carrier gas in abrasive jet machining is to accelerate fine

abrasive particles (by momentum transfer). A compressor is used to elevate
pressure of the carrier gas (as high as 20bar); abrasive grits are mixed with it in
a mixing chamber (as per mixing ratio), and a nozzle is used to convert pressure
energy into kinetic energy (in the form of high velocity jet). Carrier gas pressure
along with nozzle diameter determines final jet velocity and thus machining
performance.
Among various gases, air is commonly used in AJM as it is abundantly
available at free of cost. Sometime commercially pure carbon di-oxide and
nitrogen are also used to harness better performance for a particular purpose.
However, pure oxygen is not used as it can quickly oxidize the work surface.
Before compressing, carrier gas is dehumidified properly as presence of steam
can block pipelines. When gas is compressed to high pressure, steam may
condense and tiny water particles can create a larger globule after agglomerating
with abrasives. Carrier gas is also made dust free before compressing to high
pressure.
Nozzle used in abrasive jet machining:
Primary function of nozzle in abrasive jet machining is to convert pressure
energy of the pressurized gas-abrasive mixture into kinetic energy in the form of
high velocity jet. Nozzle also directs high velocity jet towards work surface
from a specific distance (called SOD) and at a particular predefined angle,
called impingement angle. Inner diameter of the nozzle is paramount parameter
as it determines final velocity and cross-sectional area of the jet for certain gas
pressure. As flow rate and compressor delivery pressure are constant, jet
velocity will be inversely proportional to the jet cross-sectional area.
Choosing nozzle material is another decisive factor from economic point of
view. Usually tungsten carbide (WC) or sapphire nozzles are used in industrial
applications. WC nozzles are cheaper but have limited life (20–30hr); while
sapphire nozzles have extended life (150–200hr) but are costlier. Frequent
changing of nozzle is associated with idle time during machining.

Equipment for abrasive jet machining:

 Air compressor:
It compresses the carrier gas to a pressure of 15 – 20bar. Compressor unit
also consists of drier and filter. So it removes water vapor and dust
particles to avoid condensation or jamming during compression.

 Pressure gauges:
A number of such gauges are employed for measuring pressure of carrier
gas as well as gas-abrasive mixture.

 Flow regulating valves:

These valves controls volume flow rate of carrier gas in order to
maintain constant mixing ratio.

 Hopper:
In AJM, usually circular hopper with gradual compression is employed
for continuously supplying fresh abrasive to the mixing chamber. Hopper
is sometime vibrated to avoid bridging (jamming at outlet).
  Mixing chamber:
Its purpose is to mix abrasives with pressurized carrier gas. Here
momentum transfer takes place and abrasives start flowing with carrier
gas. Chamber is vibrated to obtain homogeneous mixing.

 Nozzle:
As an isentropic steady flow device, nozzle converts hydraulic energy
(pressure) of the gas-abrasive mixture to the kinetic energy and thus high
velocity jet is obtained.

 Working chamber:
A close working chamber, inbuilt with proper exhaust system, is usually
maintained in order to avoid environmental pollution. It also helps
protecting workers from lung dieses caused by exposing into atmosphere
containing excessive tiny abrasive dust.

 Servo controller:
Sometime movement of work table is controlled by servo mechanism.
This gives easy, accurate and precise control and is suitable for cutting
intricate profiles and contours.

Process parameters and their influence on AJM:

There are many factors that can influence abrasive jet machining performance.
Important process parameters include (i) abrasive particles—its shape, size,
strength, material and flow rate; (ii) carrier gas—its nature, composition, flow
rate, pressure and temperature; (iii) abrasive jet—mixing ratio, striking velocity,
impingement angle and stand-off distance; (iv) nozzle—its profile and inner
diameter; and (v) work material—its mechanical properties and stress
concentration.
AJM performance is usually assessed by analyzing three output responses,
namely (i) material removal rate (MRR), (ii) surface roughness and accuracy of
machined feature, and (iii) nozzle life or nozzle wear rate. Effects of process
parameters on AJM performance are discussed below.
Effects of abrasives on AJM performance:
As discussed earlier, shape, size, strength, material and flow rate of
abrasive can influence machining performance. Irregular shape abrasives having
sharp edges tend to produce higher MRR as compared to spherical grits.
Smaller size grits produce highly finished surface but reduce material removal
rate (MRR) and thus productivity descends. Larger grits can again create trouble
while mixing and flowing through the pipeline. However, variation in size in the
entire volume should be low otherwise estimation or assessment will not be
accurate.
Abrasive materials have varying strength or hardness. The harder is the
abrasive with respect to work surface hardness, the larger will be the volume
removal rate. It is basically the relative hardness between abrasives and
workpiece that determines machining capability and productivity. Mass flow
rate of abrasive is usually controlled by Mixing Ratio, whose effects are also
discussed later in this section.

Effects of carrier gas on AJM performance:

Carrier gas pressure and its flow rate are two paramount factors that determine
performance and machining capability. Higher gas pressure reduces jet
spreading and thus helps in cutting deeper slots accurately. However, various
accessories including pipeline must be capable enough to handle such high
pressure without failure. Moreover, increased gas flow rate gives the provision
for utilizing higher abrasive flow rate, which can improve productivity.

Effects of mixing ratio on AJM performance:

Mixing ratio (M) is the ratio between mass flow rate of abrasive
particles and mass flow rate of carrier gas. It basically determines concentration
of abrasives in the jet. Mixing ratio can be increased by increasing abrasive
percentage and in such case an increasing trend in MRR can be noticed because
larger number of abrasives participates in micro-cutting action per unit time.
However, excessive concentration of abrasive in the jet can significantly reduce
MRR because of lower jet velocity (as gas pressure is constant) and unavoidable
collision (thus loss of kinetic energy).
 MRR can be enhanced by proportionally increasing both the abrasive
flow rate and gas flow rate at same rate so that mixing ratio remains constant. In
such case, higher pressure of the carrier gas has to be utilized. This necessitates
thicker and stronger pipelines and other accessories to smoothly handle such
high pressure without leakage and rupture. Indefinite increase in MRR is not
practically feasible because of limited capability of equipment and accessories.

Effect of stand-off distance on AJM performance:

Distance from the work surface to the tip of nozzle in abrasive jet machining
set-up is called Stand-Off Distance, abbreviated as SOD. Higher SOD causes
spreading of jet and thus its cross-sectional area increases with the sacrifice of
jet velocity. As a consequent, machining deeper slots or hole becomes difficult;
instead a wider area is cut. Alternatively smaller SOD can cut a deeper but
narrow slot or hole. It also enhances MRR. Thus an optimum value of stand-off
distance is required to set for obtaining satisfactory performance in abrasive jet
machining.

Effect of impingement angle on AJM performance:

Impingement angle (θ), also called spray angle or impact angle, is
basically the angle between the work surface and abrasive jet axis. Practically it
is kept between 60º – 90º in order to get satisfactory performance in AJM.
Larger angle tends to create deeper penetration, while smaller angle tends to
increase machining area. An impingement angle (θ) between 70º – 80º provides
better result in terms of material removal rate in abrasive jet machining.

Material removal rate and its estimation:

Knowledge of material removal rate (MRR) is beneficial for
selecting process parameters and choosing feed rate of the nozzle. It also
facilitates accurate estimation of productivity, delivery time as well as
production cost. Since only kinetic energy of abrasive grits is utilized for
erosion, the analytical formula for MRR can be established by equating
available kinetic energy with the work done required for creating an indentation
of certain cord length on a specific work material.
 However, ductile and brittle materials behave differently in indent
formation, and thus size of indentation created by the impact of single abrasive
grit is different for ductile and brittle materials. Under few assumptions, MRR
for abrasive jet machining for different materials can be modeled analytically
and can be expressed as provided below.

Process capability of abrasive jet machining:

 Materials: Hard and brittle material preferred.
 Surface finish: Down to 0.10µm achievable.
 Tolerance: ±0.10mm.
 Feature size: Minimum limit 0.10mm.
 Corner radius: Minimum limit 0.2mm.
 MRR: 15mm3/min.
 Cut thickness: 2 – 6mm plates based on material.

Advantages of abrasive jet machining:

 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
 Low capital investment

Disadvantages of abrasive jet machining:

 Not suitable for soft and ductile materials
 Abrasives are not reusable
 Abrasive collection and disposal are problematic
 Inaccurate cutting and drilling (stray cutting)
 Limited nozzle life
Applications of AJM:
Abrasive jet machining can be advantageously utilized for multifarious
purposes including surface cleaning, deburring, abrading and even making
holes. Common applications of abrasive jet machining process are provided
below. It is to be noted that, irrespective of the purpose, abrasive jet machining
(AJM) is beneficial only for hard and brittle materials. AJM should be avoided
if work material is soft and ductile; otherwise quality of machined surface will
be poor. Read also:
 Work surface cleaning: AJM can be advantageously used for cleaning
metallic or ceramic surfaces (substrate must be hard). Such cleaning
processes include removal of oxide, paint, coating, stain, glue, loose sand
particles, etc.
 Deflashing and trimming: Controlled abrasive jet machining can be
utilized for removing flash to get desired clean product with higher
dimensional accuracy and tolerance as well as sumptuous appearance.
 Engraving: As an alternative to laser beam machining, abrasive jet
machining can also be applied for incising purposes irrespective of
chemical and electrical properties of work material.
 Ceramic abrading and glass frosting: Very hard materials including
glass, refractory, stone, etc. can be easily abraded by AJM in order to get
finished surface having tight tolerance.
 Deburring: Abrasive jet machining is one of the efficient methods for
deburring (process for removal of burr) of milled features and drilled
holes, especially when work material is hard.
 Cutting and drilling hole: AJM can also be utilized for cutting various
shapes as well as for drilling holes. However, holes, slots or pockets may
lack accuracy as sharp corners cannot be obtained by this process.
REFERENCES:
 Book: Nontraditional Manufacturing Processes by G. F. Benedict
(Manufacturing Engineering and Materials Processing-19).
 Book: Unconventional Machining Processes by T. Jagadeesha (I. K.
International Publishing House Pvt. Ltd.).
 Book: Advanced Machining Processes by V. K. Jain (Allied
Publishers Private Limited).
 Book: Nonconventional Machining by P. K. Mishra (Narosa
Publishing House).
 http://www.minaprem.com/micro-machining/ajm/abrasive-jet-
machining-a-detail-overview/
 https://www.mech4study.com/production-engineering/abrasive-jet-
machining-principle-working-equipment-application-advantages-and-
disadvantages.html/