INTRODUCTION
AJM is a metal removing process and it is invented
in 1967. A jet of inert gas consisting of very fine
abrasive particles strikes the work piece at high
velocity resulting in material removal through
erosive action. This erosive action has been
employed for cutting, cleaning, etching, polishing
and debarring. This method of metal removal is
quite effective on hard and brittle materials (viz
glass, silicon, tungsten, ceramics, etc). But not so
effective on soft materials like aluminum, rubber,
etc. It can produce fine and complicated details on
the parts made of very brittle materials.
WORKING PRINCIPLE OF AJM
In Abrasive jet machining
abrasive particles are made
to impinge on work material
at high velocity.
Jet of abrasive particles
is carried by carrier gas(generally compressed air).
The high velocity stream of abrasives is generated by
converting pressure energy of carrier gas to its Kinetic
energy with the help of nozzle.
The high velocity abrasive particles remove the
material by micro-cutting action as well as brittle
fracture of the work material.
Pressure control valve
Filte
r
Abrasive feeder
Exhaust
Drier
Air-compressor
Mixing
Chambe
r
Nozzle
Workpiece
Electro-magnetic
shaker
Table
Fig 1: Schematic Diagram Of Abrasive Jet Machining Set Up
ABRASIVE JET MACHINING
CONSISTS OF 1.
Gas Propulsion System- Supplies clean and dry air.
Air, Nitrogen and carbon dioxide to propel the
abrasive particles. Gas may be supplied either
from a compressor or a cylinder. In case of a
compressor, air filter cum drier should be used to
avoid water or oil contamination of abrasive
powder. Gas should be non-toxic, cheap, easily
available. It should not excessively spread when
discharged from nozzle into atmosphere. The
propellant consumption is of order of 0.008 m3/min
at a nozzle pressure of 5 bar and abrasive flow rate
varies from 2 to 4 gm/min for fine machining and
10 to 20 gm/min for cutting operation.
2.
Abrasive Feeder- Required quantity of
abrasive particles is supplied by abrasive feeder.
The filleted propellant is fed into the mixing
chamber where in abrasive particles are fed
through a sieve. The sieve is made to vibrate at
50-60 Hz and mixing ratio is controlled by the
amplitude of vibration of sieve. The particles are
propelled by carrier gas to a mixing chamber.
Air abrasive mixture moves further to nozzle.
The nozzle imparts high velocity to mixture
which is directed at work piece surface.
3.
Machining chamber-It is well closed so that
concentration of abrasive particles around the
working chamber does not reach to the harmful
limits. Machining chamber is equipped with
vacuum dust collector. Special consideration
should be given to dust collection system if the
toxic material (like beryllium) are being
machined.
4.
AJM nozzle- AJM nozzle is usually made of
tungsten carbide or sapphire ( usually life 300
hours for sapphire , 20 to 30 hours for WC)
which has resistance to wear. The nozzle is
made of either circular or rectangular cross
section and head can be head can be straight, or
at a right angle. It is so designed that loss of
pressure due to the bends, friction etc is
minimum possible. With increase in wear of a
nozzle, the divergence of jet stream increases
resulting in more stray cutting and high
inaccuracy.
PROCESS PARAMETERS AND
MACHINING CHARACTERISTICS
The process parameters are listed below:
Abrasive
Material Al2O3 / SiC / glass beads
Shape irregular / spherical
Size 10 ~ 50 m
Mass flow rate 2 ~ 20 gm/min
Carrier gas
Composition Air, CO2, N2
Density Air ~ 1.3 kg/m3
Velocity 500 ~ 700 m/s
Pressure 2 ~ 10 bar
Flow rate 5 ~ 30 lpm
Abrasive
Jet
Velocity 100 ~ 300 m/s
N-T distance 0.5 ~ 5 mm
Impingement Angle 600 ~ 900
Nozzle
Material WC / sapphire
Diameter (Internal) 0.2 ~ 0.8 mm
Life 10 ~ 300 hours
PROCESS CAPABILITY
1. Material removal rate 0.015 cm3/min
2. Narrow slots 0.12 to 0.25mm 0.12mm
3. Surface finish -0.25 micron to 1.25 micron
4. Sharp radius up to 0.2mm is possible
5. Steel up to 1.5mm ,Glass up to 6.3mm is possible
to cut
6. Machining of thin sectioned hard and brittle
materials is possible.
[Link] OF ABRASIVE GRAIN & ABRASIVE
GRAIN SIZE
Aluminum
oxide (Al2O3), Silicon carbide
(SiC), Glass beads, crushed glass and sodium
bicarbonate are some of abrasives used in
AJM.
Selection of abrasives depends on MRR, type
of work material, machining accuracy.
We can also see the effect of grain size on
accuracy
from
Particle size
( in microns)
Surface roughness ( in
microns)
the following table.
10
0.152 to 0.203
25 to 27
0.355 to 0.675
50
0.965 to 1.27
TABLE : TYPES OF ABRASIVES & GRAIN
SIZE FOR DIFFERENT OPERATIONS
Abrasives
Grain Sizes
Application
Aluminum oxide(Al2O3)
12, 20, 50 microns
Good for cleaning, cutting
and deburring
Silicon carbide (SiC)
25,40 micron
Used for similar
application but for hard
material
Glass beads
0.635 to 1.27micron
Gives matte finish
Dolomite
Etching and polishing
Sodium bi carbonate
27 micros
Cleaning, deburring and
cutting of soft material
Light finishing below 500C
2. CARRIER GAS
Gas should be non-toxic, cheap, easily available.
Air, Nitrogen and carbon dioxide can be used.
Gas may be supplied either from a compressor or a cylinder.
In case of a compressor, air filter cum drier should be used
to avoid water or oil contamination of abrasive powder.
The carrier gas consumption is of order of 0.008 m 3/min at
a nozzle pressure of 5 bar.
3. MIXING RATIO
Mixing ratio Volume flow rate of abrasives/Volume
flow rate of gas.
Increased mass flow rate of abrasive beyond a limit will
result in a decreased velocity of fluid and will thereby
decreases the available energy for erosion and ultimately
the MRR.
Fig.2 &3. Effect Of Abrasive Flow Rate & Mixing Ratio On MRR
4. VELOCITY OF ABRASIVE JET & NOZZLE
PRESSURE
The
recommended velocity of gas abrasive mixture
ranges between 100 meter per second to 300 meter per
second depending upon the cutting or finishing
operations.
The velocity of gas abrasive mixture is a function of
nozzle design, nozzle pressure and abrasive flow rate.
.
FIG 3 & 4: Effect of jet velocity & Nozzle pressure
5. STAND OFF DISTANCE
N-T distance
Effect of stand off
distance on MRR and
accuracy can be seen
from the following
figures.
(a)
(b)
MRR
(a)
(c)
(b)
(c)
(d)
FIG 5 & 6: Stand-off distance and its effects
(d)
6. WORK PIECE MATERIAL & SHAPE OF
CUT
For
ductile materials the cutting may not be very
effective rather there will be flow of material and
actual material removal will not take place.
Hence
It
material should be brittle.
may not be possible to machine components
with sharp corners because of stray cutting. Hence
sharp corners should be avoided.
[Link] DESIGN
Nozzle material, nozzle geometry, flow rate.
The nozzle material should be
such that it can
withstand the erosive action of the abrasive particles and
should be wear resistant.
AJM nozzle is usually made of tungsten carbide or
sapphire.
The nozzle is made of either circular or rectangular cross
section.
It is so designed that loss of pressure due to the bends,
friction etc. is minimum possible.
With increase in nozzle wear, the divergence of jet stream
increases resulting in more stray cutting and high
inaccuracy.
APPLICATIONS
AJM is useful in manufacture of electronic devices.
Micro-machining of brittle objects.
Making of nylon and Teflon parts, permanent marking
on rubber stencils, cutting titanium foils.
Cutting of optical fibers without altering its wavelength
is one of the most important applications of this process.
Deburring of some critical zones in the machined parts.
Cutting, drilling and frosting of precision optical lenses.
Cutting and etching of inaccessible areas and internal
surfaces can be done.
Reproducing designs on a glass surface with the help of
rubber or copper masks.
ADVANTAGES
It has the capability of cutting holes of intricate shape in
hard materials.
Thin sections of hard & brittle materials like germanium,
mica, silicon, glass and ceramics can be machined.
Process is free from chatter and vibration as there is no
contact between the tool and work piece.
Abrasive
jet machining process creates localized
forces and generates lesser heat than the
conventional machining processes.
The power consumption in abrasive jet machining
process is considerably low.
DISADVANTAGES
The
accuracy of cutting is hampered by
tapering of hole due to unavoidable flaring of
abrasive jet.
Abrasive powders cannot be reused as the sharp
edges are worn and smaller particles can clog
the nozzle.
The mixing chamber and the nozzle are the two
critical components and they need to be
changed very frequently because of the wear.
Material removal rate in abrasive jet machining
process is rather low(around 15 mm3/min for
glass).
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