NON-CONVENTIONAL

MANUFACTURING

ABRASIVE JET MACHINING

MECHANICS OF AJM
ABRASIVE JET MACHINING
Abrasive Jet Machining, also known as
abrasive micro-blasting, pencil blasting
and micro-abrasive blasting, is an
abrasive blasting machining process
that uses abrasives propelled by a high
velocity gas to erode material from the
workpiece. Common uses include
cutting heat-sensitive, brittle, thin, or
hard materials.
DIFFERENT TYPES OF ABRASIVE USED IN
ABRASIVE JET MACHINING

Aluminum oxide (Al203) Silicon carbide

(SiC) Glass beads, Crushed Glass and
sodium bicarbonate are some of abrasive
used in AJM. Selection of abrasives
depends on MRR, type of work material,
machining accuracy.
 PARTS OF ABRASIVE JET MACHINING

• Gas supply
The filtered gas, supplied under a pressure of 2 to 8
kgf/cm to the mixing chamber containing the abrasive
powder and vibrating at 50 Hz entrains the abrasive
particles and is then passed into a connecting hose. This
abrasive and gas mixture emerges from a small nozzle
mounted on a fixture at a high velocity ranging from 150
to 300 m/min.

• Nozzle
Nozzles made of tungsten carbide have an average life of
8 to 12 hours. While nozzles of sapphire last for about 300
hours of operation when used with 27-micron abrasive
powder. The gases used are nitrogen, carbon dioxide or
clean air.
• Abrasive
Abrasive powder feed rate is controlled by the amplitude of
vibration of the mixing chamber. The gas flow and pressure
are controlled by a pressure regulator. To control the size
and shape of the cut either the workpiece or the nozzle is
moved by cams, pantographs or other suitable mechanisms.

• Workpiece
The metal removal rate depends upon the diameter of the
nozzle, the composition of the abrasive gas mixture, the
hardness of abrasive particles and that of work material,
particle size, the velocity of jet and distance of the
workpiece from the jet. A typical material removal rate for
abrasive jet machining is 16 mm/min in cutting glass.
• Pressure regulator and Foot control valve
As the names suggest, compressed carrier gas pressure has to be
regulated properly as final jet velocity relies on it. Flow rate is
also crucial parameter that can affect erosion rate (or MRR) via
mixing ratio.
 MECHANICS OF ABRASIVE JET MACHINING

In abrasive jet machining, a focused stream

of abrasive particles, carried by high
pressure air or gas is made to impinge on the
work surface through a nozzle and work
material is removed by erosion by high
velocity abrasive particles. The AJM differs
from sand blasting in that the abrasive is
much finer and the process parameters and
cutting action are carefully controlled. AJM
is mainly used to cut intricate shapes in hard
and brittle material which are sensitive to
heat and chip easily.
Process parameters of
abrasive jet
machining
 PHYSICS OF THE PROCESS
 Fine abrasive particles (0.025mm) are accelerated in a gas
stream
 The particles are directed onto the work surface by a specially
designed nozzle.
 When the particles collide with the surface, the kinetic energy
is converted into force, which erodes the material and
transports the fractured particles away.
 PARAMETRIC ANALYSIS

THE FACTORS AFFECTING THE PROCESS ARE

a) Material removal rate (MRR).
b) Geometry of cut.
c) Roughness of surface hardness.
d) The rate of nozzle wear.
Effects of Stand-off Distance on Material Removal Rate (MRR)

 The distance between the nozzle and the workpiece is defined as

Stand-off Distance (SOD) or Nozzle tip Distance (NTD).
 In AJM, SOD at 0.75mm to 1mm is typically used to achieve maximum
MRR.
 small MRR at low SOD is due to a reduction in a nozzle pressure with
decreasing distance
The decrease in MRR at large SOD
is due to a decrease in jet velocity
with increasing distance.
We must keep the SOD between
12.5-75mm for light operations
such as cleaning and frosting.
Effect of SOD on the Accuracy of the Cut

 The NTD affects not only the

MRR but also the shape and size
of the cavity produced.
 When the NTD increases, the
cavity diameter on work surface
also increases.

 Low stand-off distance provides high accuracy, reduces kerf

width, and reduces taper in groove machining.
Effects of Abrasive flow rate on MRR
As the abrasive flow rate
increases, more abrasive
particles hit the surface.
As a result, the MRR
increases.
If the abrasive flow rate
exceeds the optimum,
the velocity of the jet
decreases, and thus the
MRR decreases.
 Effects of Nozzle Pressure on MRR

 When internal gas pressure

increases the abrasive mass flow rate
increases and thus MRR increases.

 The kinetic energy of the abrasive

particles is responsible for material
removal during the erosion process.

 The minimum velocity for cutting glass with SiC particles (25
microns) has been estimated to be around 150 m/s.
Effects of mixing ratio on MRR
• MRR increases with increasing mixing
ratio up to a certain limit, then falls
due to diminishing energy available
for erosion.
• It is defined as the ratio of abrasive
volume flow rate to carrier gas
volume flow rate. It is denoted by
“ M".
 Major Process Parameters
Abrasive: Material – Al2O3 / SiC Abrasive Jet: Velocity – 100 to 300 m/s
Shape – Irregular / Spherical Mixing ratio – mass flow ratio of
Size – 10 μ to 50μ abrasive to gas
Mass flow rate – 2 ~20 mg/min Stand-off distance – 0.5 to 5mm
Impingement Angle - 60° to 90°

Carrier gas: Nozzle: Material – WC or Sapphire

Composition – Air, CO2, N2 Diameter – (Internal) 0.2 to 0.8 mm
Life – 10 to 300 hours
Density - Air ~ 1.3 kg/m3
Velocity – 500 to 700 m/s
Pressure – 2 to 10 bar
 Mathematical Modeling of AJM

A model proposed by Neema & Pandey for

Brittle Material

Where MRR = Material removal Rate (kg/s)

ρa= Abrasive particles density (kg/mm3)
Ma= Mass flow rate of abrasive particles (kg/s)
Vn= Component of particle velocity (Va) normal to the
work surface
σfw = Flow stress of work material (Pa)
 Mathematical Modelling of AJM

A model proposed by Sheldon & Kanhere for

Ductile Material

Where MRR = Material removal Rate (kg/s)

K1 = constant of proportionality
Dm = Mean diameter of abrasive grain (mm)
Va= volume of impacting particle (mm3)
ρa= Abrasive particles density (kg/mm3)
Hvw = Vicker’s Hardness number of work material
 Process Capabilities of AJM
 Intricate Details can be Produced
 Narrow Slots (0.12 to 0.25 mm) can be made
 Low Tolerances (-0.12 to +0.12mm) can be obtained
 Minimization of Taper Angle of Nozzle Work Piece
 Thin Sectioned, Brittle Material, Inaccessible areas can be
easily machined
Abrasive Jet Machining
 Abrasive Jet Machining

Abrasive jet machining is the process of impinging the high-speed

stream of abrasive particles by high-pressure gas or air on the work
surface through a nozzle and metal removal occurs due to erosion
caused by high-speed abrasive particles.
Abrasive Jet Machining parts of Construction:
 Gas Supply
 Filter
 Pressure Gauge
 Regulator
 Mixing chamber
 Nozzle
 Working Principle of Abrasive Jet Machining:

The abrasive and gas mixture comes out from the nozzle at a high velocity
ranging from 150 to 300 meters/minute and impinges over the work surface
causing abrasion action by repeated impacts and the material is removed by the
erosion. Abrasive power feed rate can be controlled by the amplitude of vibration
of the mixing chamber. Abrasive generally used are Aluminum oxide, Silicon
carbide or glass powder.
Applications of Abrasive Jet Machining:
 Cutting slots and thin sections.
 Contouring and drilling operation.
 Producing shallow crevices and deburring.
 Producing intricates hole shapes in a hard and brittle
material.
 Cleaning and polishing the plastic, nylon and Teflon
component.
 Frosting of the interior surface of glass tubes.
 Etching of marking of glass cylinders.
 Machining super-alloys and refractory material.
Abrasive Jet Machining Advantages:
 The surface finish can be obtained smooth.
 The cost of equipment is low.
 Ability to cut fragile and heat-sensitive material
without damage.
 Ability to cut intricates hole shapes in a hard and
brittle material.
 The main advantages are its flexibility, low heat
production.
Abrasive Jet Machining Disadvantages:
 The material removal rate is low.
 Poor machining accuracy.
 High nozzle wear rate.
 The soft material cannot be machined.
 Additional cleaning of the work surface is required due to the
sticking of abrasive grains in softer material.
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