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Abrasive Jet Machining
• Aluminum or Silicon
carbide abrasive grains
contained in gas or air –
for heavy cleaning
• Magnesium carbonate
for light cleaning
• Sodium bicarbonate for
light cutting
Introduction
• Oxygen never should be
used
• Mixing chamber vibrates
at 50 Hz
• Abrasive velocity 150 to
300 m/s
• Application dictates the size and the type of abrasive
• Aluminum oxide and silicon carbide- cleaning,
cutting, and debarring
• Magnesium carbonate – light cleaning and etching
• Sodium bicarbonate – fine cleaning and cutting of
soft material
• Glass beads – Polishing and de-flashing
• Foundry Sand (Garnet is 30% more effective than
sand)
• Size of abrasives range from 10 to 50 micrometer
• Powders should be free from silica dust which is
hazardous
• re-usability?
Abrasives
Process Characteristics
Masks are used to
control the location of
abrasives in restricted
areas
Material Removal Mechanism
Tiny Brittle Fracture
• The material removal rate is mainly dependent on the
flow rate and size of abrasives.
• Larger grain sizes produce greater removal rates.
AWJM
• Harder materials such as
glass, ceramics, concrete, and
tough composites can be cut by
adding abrasives to the water jet
during abrasive water jet machining
• AWJM cuts 10 times faster than the
conventional machining methods of
composite materials
• Abrasive water jet is hundreds, if
not thousands, of times more
powerful than the pure water jet
The Machining System
The Machining System
The basic machining system of AWJM incorporates the
following elements:
Water delivery
Abrasive hopper and feeder
Intensifier
Filters
Mixing chamber
Cutting nozzles
Catcher
Processing Parameters
Ice Jet Machining
• Drawback of WJM and AWJMis low efficiency of energytransfer.
• Mixing of water and abrasiveslimits the minimum jetdiameter that can be used
• Abrasives are replaced by ICE• Low MRR compared to
AWJM, however economy andenvironmental impact is high
• IJM is used in the food,electronic, medical, andspace industries wherecontamination is notpermitted
• Abrasive water jet can machine many materials that laser can not. (Reflective material such Al, copper)
• Abrasive jet do not heat your part therefore no thermal distortion or hardening of material
• Much faster than EDM
• Abrasive jet provide much nicer edge finish without heating a part comparing to flame cutting
Comparison With Other Processes
• Gas (air, Ni, Co2, inert gas) supply at 700-850 KPa
• Jet velocity 100-350 m/s
• Nozzels – WC and Sapphire
AJM System
• For glass-typical MRR are 16 mm3/min
• For metals MRR range from 1.6-4.1 mm3/min
• For hard ceramics MRR are 50% more than for glass
0
3
6
9
12
15
18
21
24
0 3 6 9 12 15 18 21 24 27 30
MR
R, m
g/m
in
Powder flow rate, g/min
MRR v/s Powder Flow Rate
0
5
10
15
20
25
30
35
0 5 10 15 20 25
MR
R, m
g/m
in
Flow rate, g/min
MRR v/s Abrasive size
10 micron
27 micron
50 micron
Process Characteristics
• Drilling and cutting small sections of glass, ceramics, or
hardened metals
• Engraving
• De-burring on metals and plastics
• Frosting glass
• Cutting intricate pattern in hard and brittle materials
• Cleaning oxides from metal surfaces
• Cleaning and trimming of electronic components
• Removing smudges and films from documents and
museum artifacts
• Machining of superhard materials
• It is typically used to ut,clean, peen, deburr, deflash, and
etch glass, ceramics, or hard metals.
Applications
• Drilling holes, cutting slots, cleaning
hardsurfaces, deburring, polishing, and radiusing
• Deburring of cross holes, slots, and threads in small
precision parts that require a burr-free finish, such as
hydraulic valves, aircraft fuel systems, and medical
appliances
• Machining intricate shapes or holes in
sensitive, brittle, thin, or difficult-to-machine materials
• Insulation stripping and wire cleaning without affecting the
conductor
• Micro-deburring of hypodermic needles
• Frosting glass and trimming of circuit boards, hybrid circuit
resistors, capacitors, silicon, and gallium
• Removal of films and delicate cleaning of irregular
surfaces because the abrasive stream is able to follow
contours
Applications
Advantages
• Best suited for machining brittle and heat-sensitive
materials like glass, quartz, sapphire, and ceramics.
• The process is used for machining superalloys and
refractory materials.
• It is not reactive with any workpiece material.
• No tool changes are required.
• Intricate parts of sharp corners can be machined.
• The machined materials do not experience hardening.
• No initial hole is required for starting the operation as
required by wire EDM.
• Material utilization is high.
• It can machine thin materials.
Limitations
• The removal rate is slow.
• Stray cutting can’t be avoided
• The tapering effect may occur especially when drilling
in metals.
• The abrasive may get impeded in the work surface
• Suitable dust-collecting systems should be provided
• Soft materials can’t be machined by the process
• Silica dust may be a health hazard
• Ordinary shop air should be filtered to remove
moisture and oil
Advanced AWJM
CAD drawing
Computer determines the starting
and end points and the sequence
of operations
Material type and tool
offset
Modules to optimize the
processing
CATIA, AUTOCAD, IGES
Feed rate and performs cutting
• No material restrictions such as electric
conductivity, magnetic properties, opaqueness etc.
Very suitable for hard and brittle nonmetals such as
glass, silicon, tungston and ceramics.
• As the tool is not shaped to conform to the produced
feature, it is mainly for cutting or slitting or drilling
and not for profiling or surface generation.
• It is however used for polishing and etching. Very
low MRR in polishing, i.e., < 0.015 cm3/min.
• An entry hole is required.
Application/Process Capability
Water Jet Machining
Water Jet Machining
The hydraulic pump is powered from a 30- kilowatt (kW) electric motorand supplies oil at pressures as high as 117 bars in order to drive areciprocating plunger pump termed an intensifier (4 bar to 3800 bar).
MACH-3 Velocity
Water Jet Machining
The accumulator maintains the continuous flow of the high-
pressure water and eliminates pressure fluctuations. It relies
on the compressibility of water (12 percent at 3800 bar) in
order to maintain a uniform discharge pressure and water jet
velocity, when the intensifier piston changes its direction.
Processing Parameters
Operating Summary
Fluid Type : Water or water with additives
Additive : Glycerin, Polyethylene Oxide or long chain polymer
Pressure : 100 to 1000 MPa
Jet Velocity : 300 to 1000 m/min
Power : Up to 40 Kw
Metal Removal Rate : 0.5 mm3/s for metals and alloys, 20 mm3/s for Elastomers
Nozzle Material : Hardened steel, WC synthetic sapphire
Water Jet Cutting Rates
• It has multidirectional cutting capacity.
• No heat is produced.
• Cuts can be started at any location without the need for
predrilled holes.
• Wetting of the workpiece material is minimal.
• There is no deflection to the rest of the workpiece.
• The burr produced is minimal.
• The tool does not wear and, therefore, does not need
sharpening.
• The process is environmentally safe.
• Hazardous airborne dust contamination and waste
disposal problems that are common when using other
cleaning methods are eliminated.
Advantages
• There is multiple head processing.
• Simple fixturing eliminates costly and complicated
tooling, which reduces turnaround time and lowers the
cost.
• Grinding and polishing are eliminated, reducing
secondary operation costs.
• The narrow kerf allows tight nesting when multiple parts
are cut from a single blank.
• It is ideal for roughing out material for near net shape.
• It is ideal for laser reflective materials such as copper and
aluminum.
• It allows for more accurate cutting of soft material.
• It cuts through very thick material such as 383 mm in
titanium and 307 mm in Inconel.
Advantages
• Low MRR
• Stray cutting
• Abrasive particles embedding
• Taper on cut geometry
Disadvantages
END