AJM Review

8/12/2019 AJM Review

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J our nal of M ater ia ls Pr ocessi ng Techn ology 39 (1993) 21-31Elsevier21

A review of abrasive jet machiningN. Ramachandran and N. RamakrishnanM echan ical En gin eer in g Depar tm ent I nd ian In sti tu te of Techn ology Powai Bombay-400 076Ind ia(Received August 13, 1991; accepted J une 20, 1992)

Industrial SummaryAbrasive jet machining is one of the unconventional machining processes which, usingvarious operations such as deburring, polishing, cutting etc., can be carried out effectivelyand efficiently, to close tolerances. In this paper, a comprehensive review of work done in thisfield is given and complex analytical findings that have been made are highlighted. Theconsiderable scope for research and the implementing of it for commercial purposes are alsopointed out.

1 IntroductionAbrasive jet machining is the process of material removal from a surface due

to the erosive action of fine-grained abrasive particles impacting at highvelocity. To attain this high velocity, the particles are allowed to pass througha nozzle with compressed carrier gas, usually air. This has the advantage overconventional machining processes of enabling the accurate control of thematerial removal rate. The development of better and newer designs, theavailability of tine-grained hard materials, and the invention of better quality,high strength, but costlier materials have called for precise and accuratemachining processes. Works done so far in this area are reviewed and ideasregarding unexplored areas are discussed in this paper. The potential of thetechnology is outlined and assessed.2 The process

Figure 1 shows a schematic representation of an abrasive jet machine asdeveloped by Kumar et al. [l], in which dry compressed air from a compressorreaches the mixing chamber through a dehumidifier and a pressure regulator,

Correspondence to: Dr. N. Ramakrishnan, Mechanical Engineering Department, IndianInstitute of Technology, Powai, Bombay-400076, India.

0924-0136/93/ 06.00 0 1993 Elsevier Science Publishers B.V. All rights reserved.


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22 N Ram acha ndra n/ A rev iew o f abras ive j e t machin ing

Fig . 1. Sche ma t i c l ay-out o f an abra s ive j e t mach ine . 1 com pres sor ; 2 pres su re gauge ;3 va lve ; 4 dehum idi f ie r and f il te r ; 5 - p res sure regu la tor ; 6 - f low mete r ; 7 to m echa nica lv ibra tor ; 8 - m ix ing cham ber ; 9 pres su re gauge ; 10 - work ing chamber ; 11 work piece ; 12work ho ld ing f ix ture ; 13 - to v acu um c leaner ; 14 - nozz le ; 15 - s econ dary ab ras ive ch amb er ;16 ~ abra s ive mete r ing tube ; 17 - m a in abras ive chamb er ; 18 abras ive m ete r ing ventur i ) .

a f lo w m e t e r b e i n g u s e d t o c h e c k t h e f lo w . T h e a b r a s i v e p a r t i c l e s f r o m t h e m a i na b r a s i v e c h a m b e r r e a c h t h e s e c o n d a r y a b r a s i v e c h a m b e r t h r o u g h a n a b r a s i v em e t e r i n g t u be . U n d e r t h e a c t i o n o f a m e c h a n i c a l v i b r a t o r , t h e a b r a s i v e p a r -t ic l e s fl o w t h r o u g h a n a b r a s i v e m e t e r i n g v e n t u r i i n t o t h e m i x i n g c h a m b e r .H e r e , t h e a b r a s i v e a n d t h e c o m p r e s s e d a i r b e c o m e m i x ed . T h e a b r a s i v e f lo wr a t e c a n b e c o n t r o l l e d b y a d j u s t i n g t h e a m p l i t u d e a n d f r e q u e n c y o f t h e v i-b r a t o r . T h e m i x i n g c h a m b e r , t h e s e c o n d a r y c h a m b e r a n d t h e m a i n a b r a s i v ec h a m b e r a r e a t th e s a m e p r e s s u r e : t h us , v i b r a t i o n c o n t r o l s t h e a b r a s i v e f lo wr a te . T h e m i x t u r e r a t i o c a n b e v a r i e d b y v a r y i n g t h e n o z z le p r e s s u r e . T h em i x t u r e , i n th e f o r m o f f in e j e t , t h e n e m e r g e s f r o m a c o n v e r g e n t - p a r a l l e l n o z zl e ,a s s h o w n i n F ig . 2, a n d s t r i k e s t h e w o r k p i e c e m o u n t e d o n a f i x t u r e i n s i d ea c l o s e d w o r k i n g c h a m b e r . A v a c u u m c l e a n e r c o n n e c t e d t o t h e w o r k i n g c h a m -b e r r e m o v e s t h e s w a r f . T h e e x p e r i m e n t a l c o n d i t i o n s e m p l o y e d a r e l i s t e d i nT a b l e 1 .

T h e d i s t a n c e b e t w e e n t h e n o z z l e t i p a n d t h e s u r f a c e o f t h e w o r k p i e c e , t e r m e dt h e s t a n d - o f f d i s t a n c e , i s c o n s i d e r e d t o b e o n e o f t h e m o s t i m p o r t a n t p a r a m e t e r st o b e c o n t r o l l e d i n t h i s p r o c e s s , t h e o t h e r c o n t r o l l a b l e p a r a m e t e r s b e i n g t h em i x t u r e r a t i o d e f i n ed a s t h e r a t i o o f t h e m a s s f lo w r a t e o f t h e a b r a s i v e p a r t i c l e st o t h e m a s s f lo w r a t e o f t h e a i r a n d a b r a s i v e m i x t u r e ) , t h e s iz e o f t h e a b r a s i v ep a r t i c l e s , t h e c h a m b e r p r e s s u r e , a n d t h e n o z z le e x i t p r e s s u r e . C o n s i d e r a t i o n o ft h e a n g l e o f i m p i n g e m e n t o f t h e j e t o n t o t h e w o r k p i e c e a n d t h e e f f e c t o f t h e f e edr a t e , e n a b l e t h e d e t e r m i n a t i o n o f t h e c o r r e c t p o s i t i o n o f t h e j e t r e l a t i v e t o t h ew o r k p i e c e .

F r o m e x p e r i m e n t a l s t u d ie s , i t h a s b e e n o b s e r v e d t h a t a b r a s i v e j e tm a c h i n i n g i s h i g h l y s u i t e d fo r d e b u r r i n g , f i n i s h i n g a n d c u t t i n g o p e r a t i o n s ,w i t h m i c r o - d r i l l in g a n d m a c h i n i n g o f t o u g h e n e d g l a s s a l s o b e i n g p o s s ib l e . I t i s


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N . R a m a c h a n d r a n / A r e vi ew o f a b ra s iv e j e t m a c h i n i n g 23t_ ~

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Fig. 2 . N ozzle desc r ipt io n (see Ta ble 1, dim ension s in m m) [1] .

T a b l e 1Exper imenta l condi t ions [1]N o z z l eM a t e r i a lHardness (HRC)Length (mm) lD i a m e t e r ( m m ) dE n t r a nc e a ng l e ( ) f lCarr i er f l u idCa r r i e r ga sI n l e t ga uge p r e s s u r e ( N m - Z )F l ow r a t e (m l m i n - 1 )M i x i ng r a t i oS o l i d p a r t i c le sT y p eSize (~tm)

H i gh c a r bon h igh c h r om i um t oo l s t ee l ( 2 .15 C ; 12Cr; 0.35 Mn; 0.2 Si; 0.8 M o)5O8.16, 10.16, 12.5, 16.180.8, 0.9, 1.17, 1.6260, 90, 120D r y a i r37.278 x 1043534.8630.096, 0.252, 0.332A120330, 38

e x p e c t e d t h a t w i t h t h e a p p r o p r i a t e c o n t r o l o f t h e v a r i o u s p a r a m e t e r s , q u a l i t ys u r f a c e s t o v e r y c l o s e t o l e r a n c e s c a n b e o b t a i n e d : i n d e b u r r i n g e s p e c i a l l y ,w h i c h s t i l l h a s u n s o l v e d p r o b l e m s in m a n y p r a c t i c a l f ie ld s, A J M m a y p l a y a ni m p o r t a n t r o l e .

3 A p p l ie d r e s e a r c hF u n d a m e n t a l , a n a l y t i c a l a n d e x p e r i m e n t a l w o r k s s u b s t a n t i a t i n g t h e a p -

p l i c a b i l i t y o f t h e e r o s i v e a c t i o n o f h a r d m a t e r i a l s i n r e m o v i n g m a t e r i a l f r o m


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24 N Ram acha ndran / A rev iew o f abrasive je t machin inga softer surface have enabled the development of a set-up for abrasive jetmachining. Erosion is described as the attack on a surface by solid particlesentrained in a fluid stream. This erosive cutting action is experienced insystems where particles move at high speeds such as in coal turbines hydrau-lic turbines coal hyd rog ena tio n equipment regenerato rs air mills etc. Whilstin these former instances the phen omenon is not desirable it has wide applica-tions in sand blasting abrasive deburring erosive drilling of hard materi alsmagnetic polishing of surfaces and electrolytic processes.The exper imental set-up shown in Fig. 1 was used by Kuma r et al. [1] to studynozzle wear during the flow of an ai r-abrasive mixture where parameters suchas nozzle length diameter and entrance angle mixtu re ratio and grain sizecould be varied. The results as shown in graphical form in Fig. 3 indica tedthat increase in nozzle length decrease in nozzle diameter and decrease in theent ran ce angle of the nozzle increased nozzle wear. Later for pre-decided setcondit ions and considering the effects of various parameters based on erosionmodels the erosion rate diameter of eroded cavity and depth of penet ratio nwere studied by Verma and Lal [2] the ir resu lts being presented in the form ofgraphs in Fig. 4. It was observed that there is an opt imum stand-off distance formaximum material-removal rate this aspect being attr ibute d to the inertia ofthe suspended particle. For the penet ratio n rate to be optimum the stand-offdistance is different from this since the penetrat ion ra te is essentially a func-tion of the impingement velocity and not of the impingement area. Consideringthe impingement angle and the feed rate as additional parameters to the abovestudies conducted by Venkatesh [3] provided results shown in Fig. 5 supple-menti ng earlier theoretical works. However these studies did not attemp t tomake use of the experimental observations to justify fully the analyticaltreatment. The conclusions from the experiments were not sufficient to enablethe auth ori tati ve prediction of the effects of various parameters and an opti-mum particle size could not be arrived at.A new surface finishing operation using abrasives in magnetic fields hasbeen tried successfully by Shinmura et al. and a spindle finish type apparatushas been developed [4-10]. This process has been found to be very effective inedge finishing plane finishing deburr ing operations etc.Experiment al works using loose abrasives mixed in an aqueous solution ofsodium nitrate has been found to be surprisingly successful in mirror finishingto very close tolerances [11 12] in stainless steel.Hashish [13] has carried out extensive work on abrasive water jet machin-ing. Abrasive wat er jets are found to be very effective in metal cutti ng: cu tti ngaircra ft composites metals circu it boards etc. This has already foundwide applic ations in the fields of automotives aerospace defence buildingsupplies fab ric ation shops food glass job shops mining oil and gas wellspackaging paper rubber shipyards and material service centres in the UnitedStates. The use of high energy abrasive water jets in mac hin ing a wide vari etyof non-metals and metals across several industries has been reported byManson [14].


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N Ram acha ndran / A rev iew o f abras ive j e t machin ing 2 50.30

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F i g . 3 . V a r i a t i o n i n n o z z l e w e a r w i t h o p e r a t i n g t i m e f o r v a r i o u s p a r a m e t e r s : ( a) r a t i o s o fn o z z l e l e n g t h t o n o z z l e d i a m e t e r ; ( b) p a r t i c l e s iz e ; ( c) n o z z l e d i a m e t e r ; ( d) e n t r a n c e a n g l e ; (e )m i x i n g r a t i o s . T h e t e s t c o n d i t i o n s a r e : ( a ) d = 0 . 9 7 r a m , f l = 6 0 , p a r t i c l e s i z e = 3 8 p m ,m i x i n g r a t i o = 0 .2 5 2 ; ( b ) d = 0 . 9 7 m m , l = 8 . 1 6 m m , ,8 = 6 0 , p a r t i c l e s i z e = 3 8 p m , m i x i n gr a t i o = 0 . 2 5 2; ( c) d = 1 2 m m , = 6 0 , p a r t i c l e s i z e = 3 8 p m , m i x i n g r a t i o = 0 .2 5 2 ; ( d )d = 0 . 9 6 m m , l = 5 .2 8 m m , p a r t i c l e s i z e = 3 8 p ro , m i x i n g r a t i o = 0 .2 5 2 ; ( e) d = 0 .9 7 m m ,l = 8 .1 6 m m , fl = 6 0 , p a r t i c l e s i z e = 3 8 p m . ( T h e w e a r i n d e x i s t h e r a t i o o f t h e d i f f e r e n c e i nt h e f i n a l a n d i n i t i a l v o l u m e o f t h e n o z z l e f lo w c h a n n e l t o t h e i n i t i a l v o l u m e o f t h e n o z z l e f lo wc h a n n e l , d e t a i l e d i n F i g . 2 [ 1] .)


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26 N Ra ma chan dran /A rev iew o f abras ive je t mach in ing

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F i g . 4 . E f f e c t o f p a r a m e t e r s o n t h e m a t e r i a l r e m o v a l r a t e a n d t h e p e n e t r a t i o n r a t e w i t h t h ep r e s s u r e c o n s t a n t a t 1 4 7. 15 k N / m 2 g a u g e ) : a ) p e n e t r a t i o n ra t e , v o l u m e t r i c m a t e r i a lr e m o v a l r a t e , h a t c h e d t r i a n g l e s d e n o t e t h e p r o f i l e s o f t h e m a c h i n e d c a v i t y p a r t i c l e s i z e= 3 0 p m , m i x i n g r a t i o = 0 .1 4 8 , c u t t i n g t i m e = 6 0 s ); b ) m i x i n g r a t i o p a r t i c l e s i z e = 3 0 ~ m ) ;c ) m i x i n g r a t i o p a r t i c l e s i z e = 3 0 ~ m ) ; d ) p a r t i c l e s i z e m i x i n g r a t i o = 0 . 1 48 ) [ 2] .

A brief summary of the fundamental and analytical works undertaken bynumerous eminents into the cu tting action of fine-grained hard mate rials willenable greater appreciation of this non-traditional machining process.4 . T h e o r e t i c a l w o r k s4 1 P a r t i c l e im p a c t

The first study of the problem of particle impact onto different shapes wasdone in Ger many in 1931 in connect ion with the collection of smoke and dustparticles as reported by Finnie [15]. Lat er studies in 1940 by Taylo r and man y


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N Ramachandr an A review of abrasive je t mach in ing 7

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F i g . 5 . E f f e c t o f v a r i o u s p a r a m e t e r s o n t h e m a t e r i a l r e m o v a l r a t e [ 5 ] : ( a ) g r i t s iz e ; (b ) f e e dr a t e ; ( c ) n o z z l e p r e s s u r e ; (d ) s p r a y a n g l e . ( S t a n d - o f f d i s t a n c e = 5 ra m , d = 3 .5 r a m , s p r a y a n g l e(a -c ) = 90 ) .

o t h e r s w i t h r e s p e c t t o s p e c i f i c a e r o f o i l s , in l e t d u c t s a n d o t h e r s h a p e s , g a v ei n s i g h t i n t o m o r e p r o b l e m s o n p a r t i c l e i m p a c t i o n . T h e r e p o r t b y F i n n i e s h o w st h a t a s u r v e y o f t h e l i t e r a t u r e o n e r o s i o n u p t o 1 94 6 c o u l d n o t t h r o w l i g h t o n t ot h e m e c h a n i s m o f m a t e r i a l r e m o v a l b y e r o s i o n . F u r t h e r , r e s u l t s o f s o m e e x p e r i-m e n t a l s t u d i e s c o n d u c t e d w e r e n o t i n a g r e e m e n t w i t h p r a c t ic a l f i n d i n g s . L a t e r ,e r o s i o n t e s t s w i t h d i f f e r e n t a n g l e s o f i m p i n g e m e n t c a r r i e d o u t b y W e l l i n g e ra n d h i s c o l l e a g u e s [ 1 6 - 2 0 ] , a s r e f e r r e d t o b y F i n n i e [1 5] , w e r e c o n s i d e r e d a s t h ef ir s t a t t e m p t t o c o l l e c t d a t a o n t h e p r o c e s s o f e r o s i o n u n d e r v a r i o u s c o n t r o l l e dc o n d i t i o n s , a t t r i b u t i n g t h e l o s s o f w e i g h t i n e r o s i o n t o t w o p r o c e s s e s , c a l l e d


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28 N . Ramachandr anjA review of abrasive et machiningrub erosion and shock erosion. However, the data could not be correlatedwith the physical properties of the materials or with the material removal. Thetype of erosion prevailing was dependent on the mechanical properties of theeroded material, but it was generally accepted that it was some of the factors ofthe wear process that were responsible for the material removal.

4.2. WearThe process of wear is the loss of material removal when two surfaces are in

sliding contact. Even though the Coulomb laws of friction have been known forover two hundred years, it has not been possible to deduce any general laws ofwear. A survey of the possible wear mechanisms has been conducted byBurwell [21]. This, and various other studies conducted, were further modifiedand classified by Shaw [22]. Of these classifications, adhesive wear and abras-ive wear are of great importance in mechanical systems. Using theories byHolms [23], experiments have been conducted to investigate the laws of ad-hesion [24]. Adhesive wear studies have also been made by Shaw [22]. Onabrasive wear, much study have been done by Rabinowicz and Mutis [25],Dunn and Russel [26] and Richardson [27, 281. Emphasising the wide range ofvariables that can influence the abrasive wear of materials, a review of two-body abrasive wear was carried out by Moore [29], where only the sliding ofparticles on a surface was considered. When the movement of particles relativeto one another and rotation whilst sliding across the wearing surface is to betreated, the study of three-body abrasive wear must be considered. In abrasivejet machining, this theory has great significance, since the various abrasiveparticles in a jet striking a surface will be subjected to both rotation andsliding. A classification of three-body abrasive wear has been made by Misraand Finnie [30], followed by a generalized review of abrasive wear [31]. Thesestudies throw more light onto the theories of abrasive wear, and make use ofthe past works of Richardson, Rabinowicz et al.

4.3. Ultrasonic machiningVarious authors have applied the adhesive and abrasive properties of wear

in developing ultrasonic machining to its present state. In ultrasonic machin-ing, the high velocity impact of free moving abrasive particles onto the work-piece with direct hammering of the abrasives by a tool is employed for materialremoval. The works of Shaw [32], Kainth et al. [33], Kremer et al. [34] VijayanNair [35], Sundararajan, and Radhakrishnan [36] are notable in ultrasonicmachining. Recent studies by Matsuo [37] on the grain-wear characteristics ofgeneral and super-hard abrasive grains, including diamond and cubic boronnitride (CBN), against hard materials such as stellite, sintered alumina, ferrite,etc., at high speeds and small loads, have made it possible for the relative wearranking of grains. An expression for wear mass per unit distance moved bya particle along a surface, in terms of maximum flow pressure and the hardnessof the metal, the abrasive particle shape and the total coefficient of friction has


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N Ramachandran/A review of abrasive jet machining 29b e e n o b t a i n e d b y G o d d a r d a n d W i l m a n [3 8]: t h is t h e o r y m a y b e o f s o m e h e l pi n c o m p u t i n g t h e v o l u m e o f m a t e r i a l r e m o v e d i n t h e a b r a s i v e j e t m a c h i n i n gp r o c e s s .

4 4 Eros ive wearS t u d i e s o n t h e n e x t i m p o r t a n t c l a s s i f i c a t i o n u n d e r w e a r , i.e ., e r o s i v e w e a r ,

h a v e b e e n d e a l t w i t h i n d e t a i l b y F i n n i e [3 9]. T h e e r o s i o n p r o b l e m w a s d i v id e di n t o t w o m a j o r p a r t s : i) d e t e r m i n a t i o n , f r o m fl u id - fl o w c o n d i t i o n s , o f t h en u m b e r , d i r e c t io n a n d v e l o c i t y o f t h e p a r t i c l e s s t r i k i n g t h e s u r f a c e , w h i c h i sa t w o - p h a s e - f l o w p r o b l e m ; a n d ii ) c a l c u l a t i o n o f t h e a m o u n t o f s u r f a c e m a t e r -i a l r e m o v e d . F i n n i e f o u n d t h a t t h e e r o s i o n o f d u c t i l e a n d b r i t t l e m a t e r i a l s i sd e p e n d e n t o n a b r a s i v e p r o p e r t i e s s u c h a s t h e s iz e, t h e s h a p e , t h e h a r d n e s s , t h es t r e n g t h a n d t h e a n g l e o f i m p a c t o f t h e p a r t i c le s , e m p i r i c a l r e l a t i o n s h i p s f o rm a t e r i a l r e m o v a l b e i n g a r r i v e d a t . I n 1 963 , B i t t e r [4 0, 41 ] b r o u g h t o u t a d e t a i l e dr e p o r t o n s t u d i e s m a d e o n w e a r a n d d e r i v e d e x p r e s s i o n s f o r e r o s i o n a s f u n c -t i o n s o f t h e m a s s a n d t h e v e l o c i t y o f t h e i m p i n g i n g p a r t ic l e s , t h e i m p i n g e m e n ta n g l e a n d t h e m e c h a n i c a l a n d p h y s i c a l p r o p e r t i e s o f b o t h t h e e r o s i v e p a r t i c l e sa n d t h e e r o d e d b o d y . M o d i f i c a ti o n o f t h e e m p i r ic a l r e l a t i o n s h i p s b y a p p l y i n gt h e t h e o r i e s o f t h r e e - b o d y a b r a s i v e w e a r , t h e d e t e r m i n a t i o n o f t h e d i s t r i b u t i o no f p a r t i c l e s a n d t h e d i s t r i b u t i o n o f v e l o c i t y o f p a r t i c le s m a y l e a d t o a n e x a c te x p r e s s i o n f o r m a t e r i a l r e m o v a l r a t e i n a b r a s i v e j e t m a c h i n i n g .A n o t h e r a s p e c t o f e r o s i v e w e a r b y s o li d p a r ti c l e s w a s e x p l a i n e d b y F i n n i ea n d K a b i l [ 42 ]. S i m i l a r t o t h e r i p p l e p a t t e r n s a p p e a r i n g i n s a n d d e s e r t s a n d i nr i v e r b e ds , w h e n a b r a s i v e p a r t i c l e s s t r i k e d u c t i l e m a t e r i a l s a t s m a l l a n g le s o fi m p i n g e m e n t a g r a d u a l t r a n s i t i o n f ro m a s u r f a c e w i t h ra n d o m r o u g h n e s s t oo n e i n w h i c h w e l l d e v e l o p e d r i p p le s a r e f o r m e d t a k e s p l a c e. T h e f o r m a t i o n o fs u r f a c e r i p p le s d u r i n g t h e e r o s i o n o f v a r i o u s s p e c i m e n s w a s o b s e r v e d b y t h e s ea u t h o r s , t h u s c o n f i rm i n g t h e i r t h e o r y . I n s u b s e q u e n t w o r k o n th e m e c h a n i s m o fm a t e r i a l r e m o v a l b y a n e n e r g y a p p r o a c h , i n w h i c h t h e v o l u m e r e m o v a l w a st a k e n a s a f u n c t i o n o f t h e k i n e t i c e n e r g y o f t h e e r o d i n g p a r t ic l e s , F i n n i e a n dS h e l d o n [ 43 ] p r e d i c t e d t h e v o l u m e o f m a t e r i a l r e m o v e d a n d i t s a p p l i c a b i l i t yo v e r a r a n g e o f p a r t i c l e s iz e s a n d v e l o c i t i e s . In a b r a s i v e j e t m a c h i n i n g , t h e s ew o r k s w i l l b e o f m u c h h e l p i n e s t i m a t i n g c o r r e c t l y t h e d i s t r i b u t i o n o f p a r t i c le sa n d t h e d i s t r i b u t i o n o f t h e v e l o c i t i e s o f t h e p a r t i c le s .5 F i e l d s o f a p p l i c a t io n

I n v a r i o u s p r o c e s s e s w h e r e m a t e r i a l r e m o v a l r a t e i s i m p o r t a n t , a b r a s i v e j e tm a c h i n i n g h a s a n i m p o r t a n t r o l e to p la y . T h e p o l i sh i n g o f s u r f a ce s , d e b u r r in g ,a n d f i n is h i n g o p e r a t i o n s c a n b e c a r r i e d o u t e f f e c t iv e l y u s i n g a b r a s i v e j e tm a c h i n i n g . O r d i n a r y , o p t i c a l a n d to u g h e n e d g l a ss a re m a c h i n e d e a s i l y b y t h i sp r o c e s s. B r i t t l e m a t e r i a l s , f o r w h i c h c o n v e n t i o n a l m a c h i n i n g p r o c e s s e s m a yc a u s e p r a c t i c a l d if fi cu lt ie s a n d v a s t c h a n g e s i n m a t e r i a l p r o p e r t ie s , c a n b em a c h i n e d e a s i l y an d s u c c e s s f u l l y u s i n g a b r a s i v e j e t m a c h i n i n g .


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30 N. Ramachandran/ A review of abrasive jet machining6 C o n c l u d i n g r e m a r k s

C o n s i d e r i n g t h e p o s s i b i l i t i e s o f a b r a s i v e j e t s t o c u t a n d m a c h i n e v a r i o u sm e t a l s a n d n o n - m e t a l s , s t u d i e s r e l a t e d t o th e m a c h i n i n g o f c o m p o s i t e m a t e r i a l sc a n n o t b e o v e r r u l e d . H o w e v e r , r e p o r t s o n t h e s t u d y o f g e o m e t r i c a c c u r a c y ,s u r f a c e f i n is h , s u r f a c e h a r d n e s s , s u r f a c e e r r o r s , e t c. , w h e n e m p l o y i n g t h i sp r o c e s s a re y e t to b e p u b l i s h e d a n d t h e v a r i o u s p a r a m e t e r s t o b e c o n s id e r e d a r en o t y e t c o m p l e t e l y u n d e r s t o o d . I n a b r a s i v e w a t e r - j e t m a c h i n i n g , m o r e t h a nt w e n t y - f i v e p a r a m e t e r s h a v e b e e n i d e n t if ie d , w h e r e a s i n a b r a s i v e j e t m a c h i n -i n g , o n l y v e r y f e w h a v e b e e n i d e n t i f i e d . E m p i r i c a l r e l a t i o n s h i p s t o d e t e r m i n et h e m a t e r i a l r e m o v a l r a t e r e m a i n u n - m o d i f i e d , s i n c e a n a l y t i c a l w o r k o n t h ee f f e c ts o f t h e p a r t i c l e d i s t r i b u t i o n i n t h e a i r - a b r a s i v e m i x t u r e s t r e a m , o f t h ev e l o c i t y d i s t r i b u t i o n o f t h e s e p a r t i c l e s a n d o f t h i s c o m b i n a t i o n , o n t h e m a t e r i a lr e m o v a l r a t e , e t c . , a r e y e t to b e c o n d u c t e d . F u r t h e r , t h e w e a r o f t h e n o z z l e a n dt h e m e a n s o f r e d u c i n g t h e l a t t e r b y u s in g s a p p h i r e , u n i d e n t i f i e d c e r a m i c s , e tc .,a r e y e t to b e s t u d i ed . T h u s , m u c h s c o p e e x i s t s f o r f u r t h e r w o r k i n t h e f ie ld o fa b r a s i v e j e t m a c h i n i n g , w h i c h i s s t i ll in t h e e a r l y s t a g e s o f d e v e l o p m e n t . I t m a yb e a s s u m e d s a f e ly t h a t o n c e a b e t t e r u n d e r s t a n d i n g o f t h e p r o c e s s i s a c h i e v e d ,A J M w i l l b e c o m e a v e r y a t t r a c t i v e c o m m e r c i a l p r o c e s s fo r u s e in d e b u r r i n g ,c u t t i n g , p o l i s h i n g , e t c .

R e f e r e n c e s[1] R. Ku m ar, A.P. Ve rm a and G.K. Lal , Nozzle we ar dur in g th e f low of a gas - p ar t ic lemix ture , Wear 91 1983) 33-43.[2] A .P . Ve rm a and G.K. La l, An expe r ime nta l s tudy of abra s ive j e t machin ing , Int. J. M. T.Des. Res. 24 1 ) 1984) 19-29.[3] V .C. Ve nka tesh , P a ra m et r i c s tud ies on abras ive j e t machin ing , Ann. CIRP 33 1) 1984)109-112.[4] T . Sh inm ura , K . Tak azaw a , E . Ha ta no and T . Aizawa , S tudy of m agn e t i c abra s iveproc ess -o Pro cess p r incip le an d f inishin g po ss ibi l i ty , Bull. JSPE 19 1) 1985) 54-55.[5] T . Sh inmura , K . Takazawa and E . Ha tano , S tudy on magne t i c abras ive proces s - Ap-p l i ca t ion to edge f in i sh ing , Bull. JSPE 19 3 ) 1985) 218-220.[6] T . S h i nm ur a , K . T a k a z a w a a nd E. H a t a n o , S t udy on m a g ne t i c a b r a s i ve p r oc e s s A p-p l i ca t ion to p la ne f in i sh ing , Bull. JSPE 19 4) 1985) 289-291.[7] T . Sh inm ura , K . Tak azaw a and E . Ha tano , S tudy on ma gne t i c abras ive f in ish ing Ef fec tsof m achin ing f luid on f in i sh ing ch arac te r i s t i c s , Bull. JSPE 20 1) 1986) 52-54.[8] T . Sh inm ura , K . Ta kaz aw a and E . Ha ta no , Dev e lopm ent of sp ind le fin ish type f in i sh inga pp a r a t u s a nd i t s f in i sh i ng pe r f o r m a nc e u s i ng a m a gne t i c a b r a s i ve m a c h i n i ng p r oc e ss ,Bull. JSPE 20 2 ) 1986) 79-84.[9] T . Sh inm ura , K . Ta kaz aw a and E . H a tan o , S tudy of m agn e t i c abra s ive f in i sh ing Ef -f e c ts o f va r i ous t ype s o f m a gne t i c a b r a s i ve s on f in i sh i ng c h a r a c t e r i st i c s , Bull. JSPE21 2) 1987) 139-141.[10] T . S h i nm ur a a nd T . A i z a w a , S t udy on i n t e r na l f in i sh i ng o f a non f e r r om a gne t i c t ub i ng bym a g ne t i c a b r a s i ve m a c h i n i ng p r oc e s s, Bull. JSPE 22 1) 1989) 37-41.[11] H . M aeh a ta a nd H . Kam ada , S tud ies on e l ec t ro s t a t i c abras iv e mi r ror f in i sh ing i i) .Rou ghness of f in ished sur face , Bull. JSPE 19 2) 1985) 131-132.


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N. Ramachandran/ A review of abrasive jet machining 31[12] H. Kamada, K. Tamiya, S. Honda, H. Maehata and Y. Kimoto, A study of electrolyticabrasive mirror fini shing - using loose abrasives mixed in the electrolyte, Bull. JSPE

16 2) 1982) 109-110.[13] M. Hashish, Tur nin g with abrasive water jets A first investigation, Trans. ASME J.Eng. Ind. 109 1987) 281-290.[14] Frederick Manson, Water and sand cut it, Special Report 807, American Machinist

1989) 84-95.[15] Iain Finnie, Erosion of surfaces by solid particles, Wear 3 1960) 87 103.[16] K. Well inger and H.C. Brockstedt, Gluckauf 78 1942) 130.[17] K. Wellinger and H.C. Brockstedt, Stahl Eisen. 62 1942) 635.[18] K. Wellinger, Metall Kunde 40 1949) 361.[19] K. Wellinger and H. Uetz, Ver. deut Ingr. 96 1954) 43.[20] K. Well inger and H. Uetz, Forschungsheft, 1955), 449, Wear 1 1957/58) 225.[21] J.T. Burwell Jr, Survey of possible wear mechanisms, Wear 1 1957/58) 119-141.[22] M.C. Shaw, F und amenta ls of wear, Ann. CIRP 19 1971) 533-543.[23] Ragner Holms, Electric Contacts - Theory and Applications Springer, New York, 1967.[24] J.T. Burwell and C.D. Strang, On the empirical law of adhesive wear, J. Appl. Phys.

23 1) Jan 1952) 18-28.[25] E. Rabinowicz and A. Mutis, Effect of abrasive particle size on wear, Wear 8 1965)381 390.[26] E. Rabinowicz, L.A. Dun n and P.G. Russel, A study of abrasive wear u nde r three bodyconditions, Wear 4 1961) 345-355.[27] R.C.D. Richardson, The wear of metals by hard abrasive, Wear 10 1967) 291-309.[28] R.C.D. Richardson, The maximum hardness of str ained surfaces and the abrasive wearof metals and alloys, Wear 10 1967) 353-382.

[29] M.A. Moore, A review of two body abrasive wear, Wear 27 1974) 1 17.[30] A. Misra and I ain Finnie , A classification of three body abrasive wear and design ofa new tester, Wear 60 1980) 111 121.[31] A. Misra and Ia in Finnie , A review of the abrasive wear of metals, Trans. ASME J. Eng.Mater. Technol. 104 1982) 94-101.[32] M.C. Shaw, Ultrasonic grinding, Microtecnic 10 6) 1956) 257.[33] G.S. Kainth, A. Nandy and K. Singh, On the mechanics of material removal in ultra-sonic machining, Int. J. Mach. Tool Des. Res. 19 1) 1979).[34] D. Kremer, S.M. Saleh, S.R. Gabrial and A. Moisan, The state of the art of ultrasonicmachining. Ann. CIRP 30 1) 1981) 107 110.[35] E.V. Nair, Mechanics of material removal in ultr asoni c machini ng and improvement ofperformance characteristics, Ph.D Thesis Dept. of Mech. Eng., IIT Kanpur, India,1 9 8 3 ) .

[ 3 6 ] V . S o u n d a r a r a j a n a n d V . R a d h a k r i s h n a n , A n e x p e r i m e n t a l i n v e s t i g a t i o n o f t h e b a s i cm e c h a n i s m s i n v o l v e d i n u l t r a s o n i c m a c h i n i n g , I n t . J . M a c h . T o o l D e s . R e s . 2 6 3 ) 1 9 8 6 )3 0 7 - 3 2 1 .

[ 3 7 ] T . M a t s u o a n d K . O k a m u r a , W e a r c h a r a c t e r i s t i c s o f g e n e r a l a n d s u p e r h a r d a b r a s i v eg r a i n s a g a i n s t v a r i o u s h a r d m a t e r i a l s , A n n . C I R P 3 0 1 9 8 1 ) 2 3 3 2 3 6 .

[ 3 8 ] J . G o d d a r d a n d H . W i l m a n , A t h e o r y o f f r i c t i o n a n d w e a r d u r i n g t h e a b r a s i o n o f m e t a l s ,W e a r 5 1 9 6 4 ) 1 1 5 - 1 3 5 .

[ 3 9 ] l a i n F i n n i e , S o m e o b s e r v a t i o n s o n t h e e r o s i o n o f d u c t i l e m e t a l s , W e a r 1 9 1 9 7 2 ) 8 1 - 9 0 .[ 4 0 ] J . G . A . B i t t e r , A s t u d y o f e r o s i o n p h e n o m e n a , P a r t i , W e a r 6 1 9 6 3 ) 5 2 1 .[ 4 1 ] J . G . A . B i t t e r , A s t u d y o f e r o s i o n p h e n o m e n a , P a r t 2 , W e a r 6 1 9 6 3 ) 1 6 9 - 1 9 0 .[ 4 2 ] I a i n F i n n i e a n d Y . H . K a b i l , O n t h e f o r m a t i o n o f s u r f a c e r i p p l e s d u r i n g e r o s i o n , W e a r

8 1 9 6 5 ) 6 0 - 6 9 .[ 4 3 ] G . L . S h e l d o n a n d l a i n F i n n i e , T h e m e c h a n i s m o f m a t e r i a l r e m o v a l i n t h e e r o s i v e c u t t i n g

o f b r i t t l e m a t e r i a l s , T r a n s . A S M E J . E n g . I n d . N o v 1 9 6 6 ) , 3 9 3 - 4 0 0 .

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