Review Article Abrasive Jet Machining-Research Review
Review Article Abrasive Jet Machining-Research Review
Review Article
ABRASIVE JET MACHINING- RESEARCH REVIEW
1
D V Srikanth, 2Dr. M. Sreenivasa Rao
abrasive particles at various Air pressures.Observed impact angle. The erosion rate was maximum at
that MRR has increased with increase in grain size around 25◦ relative to the surface, suggesting a ductile
and increase in nozzle diameter. The dependence of erosion mechanism. [18].
MRR on standoff distance reveals that MRR
increases with increase in SOD at a particular
pressure. [4].
Varma & Lal (1984) explained about the effect of
Nozzle Pressure on MRR and Effect of SOD on
MRR for various Mixing ratios. The Variation in
Pressure is clearly indicated with the help of graphs.
[5]. Fig 6 –Cross-sectional Profiles of Masked surfaces at
Finnie (1960) showed that volume of Material (Q) different Passes [18]
eroded by impacting Particles of mass M carried in a Wakuda Manabu et al (2001) described an elementary
stream of air can be calculated as approach to the characterization of fundamental AJM
Q = Cf (ѳ) M vn, properties for silicon nitride. In dimpling of the Si3N4
Where C& n are constants σ s =Minimum flow stress surface, the material removed was identified by mild
of work material, ѳ is Impingement Angle. [6]. wear within the grain particles in a manner resembling
Sarkar & Pandey (1980) suggested a model to ductile behavior. [20].
calculate MRR (Q) during AJM. Ghobeity, H. Gateau et al (2007) Explained Poor
Q = x Zd3v3/2 (ρ/12Hw)3/4, repeatability of the erosion rate in a pressure feed
Where Z is no of particles impacting per unit time, D AJM system was traced to uncontrolled variation in
is the mean diameter of Abrasive grain, Ρ is the the abrasive particle mass flux caused by particle
density, V is the velocity of abrasive particles, how is packing and local cavity formation in the reservoir.
hardness of work material, X is a constant. [7]. [21].
Bhaskar Chandra Kandpal et al (2011) conducted V. C. Venkatesh (1984) was Performed Parametric
Experimentation on machining of Glass and Studies on Abrasive Jet Machining and explained
Ceramics with various types of Abrasives by the effect of feed rate, pressure, abrasive grit size,
changing pressure, nozzle tip distance on different spray angle, nozzle tip to work distance, and metal
thickness of glass plates and ceramic plates. The removal rate are reported. [23].
effect of process parameters of compared with V. C. Venkatesh, T. N. Goh et al (1989) reported a
theoretical results. The photos of the specimens study of the results of machining under various
Machined are shown below. [11]. conditions. A commercial AJM machine was used,
with nozzles of diameter ranging from 0.45 to 0.65
mm, the nozzle materials being either tungsten
carbide or sapphire, both of which have high tool
lives. Silicon carbide and aluminum oxide were the
two abrasives used. The materials machined were
glass, ceramics, and electro-discharge machined
Fig. 3- Samples of glass plate cut by AJM (11) (EDM) dies steel. [24].
Manabu Wakuda, Yukihiko et al (2003) presented a
paper attempts to identify the material response of
alumina ceramics to the abrasive particle impact in
the AJM process. They used three kinds of
commercial abrasive particles to dimple the sintered
Fig. 4 - Samples of ceramic plate cut by AJM (11 alumina samples, aluminum oxide (WA), silicon
El-Domiaty et al (2009) are conducted the experint carbide (GC) abrasive, and synthetic diamond (SD)
on the drilling of Glass with AJM. The abrasive grits abrasive. [25].
(sand) were mixed with an air stream ahead of the T Burzynski and M Papini (2011) The spatial
nozzle and the abrasive flow rate was kept constant distribution of particles within the jet was found by
throughout the machining process. [12]. using a direct particle capture technique, and was
found to depend on the nozzle diameter, following
either a Weibull or a piecewise Weibull distribution
[27].
D.S. Robinson Smart (2011) designed and fabricated
a set up in order to investigate the effect of Standoff
Distance (SOD), horizontal and vertical angle
Fig 5 –Drilling of Glass at different SOD’s [12] between the work piece and abrasive jet nozzle and
Linden et al (2001) investigated abrasive machining the exit diameter of abrasive jet nozzle on coating
characteristics of a glass-infiltrated alumina used for removal rate. [28].
fabrication of all-ceramic dental crowns were Shanmugam and Masood (2009) presented an
investigated using a high-speed dental hand piece and investigation on the kerf taper angle generated by
diamond burs with different grit sizes. [14]. abrasive water jet (AWJ) technique to machine two
Bhaskar Chandra &Jag tarSingh (2011) carried out types of composites: epoxy pre-impregnated graphite
experimental studies to investigate the influence of woven fabric and glass epoxy. Comprehensive
process parameters like Nozzle Tip Distance, Mass factorial design of experiments was carried out in
flow rate, Gas pressure on Metal Removal Rate. [17]. varying the traverse speed, abrasive flow rate,
H. Gateau et al (2007) measured the fundamental standoff distance and water pressure. [30].
erosion rate of polymethylmethacrylate (PMMA) with Shanmugam et al. (2008) An experimental
a stream of 25um Al2O3 particles as a function of investigation was carried out by tominimize or
Int J Adv Engg Tech/Vol.Electronic copy available at: https://ssrn.com/abstract=3682998
V/Issue II/April-June,2014/18-24
Srikanth et al., International Journal of Advanced Engineering Technology E-ISSN 0976-3945
eliminate the kerf taper in AWJC of alumina etching and grooving is discussed in this article. The
ceramics by using a kerf-taper compensation roughness of machined surface are also analyzed. It is
technique. [31]. found that the Material Removal Rate (MRR)
A. Ghobeity et al (2008) presented model increases as the temperature of carrier media (air) is
predictions and experimental data related to the increased [16].
abrasive jet micromachining of masked and Matthew W. Chastagner Explained about the edge
unmasked channels in glass. The spatial and velocity with a consistent and precise shape is important for
distributions of particles in the jet of an abrasive jet highly stressed mechanical components. This study
micromachining (AJM) setup were measured using a investigates the generation, measurement, and
novel technique. [33]. definition of edges. Abrasive jet machining, a flexible
R. H. M. Jafar et al (2013) presented experimental process ideal for difficult-to-reach areas, is applied for
data on the effect of particle size, velocity, and angle edge generation. The SEM micrographs AJM and
of attack on the Surface roughness of unmasked edges are established as shown in Figure [19].
channels machined in borosilicate glass using AJM.
Single impact experiments were conducted to
quantify the damage due to the individual alumina
particles. Based on these observations, the assumed
location of lateral crack initiation in a relatively
simple analytical model from the literature was
modified, and used to predict the roughness and
erosion rate. [38]. Fig 7- SEM micrographs AJM Region and edges [19]
Stephen Wan et al. (2010) present simple Srinivasu et al. (2009) investigated the influence of
deterministic process models for the prediction of the key kinematic operating parameters (i.e. α-jet
evolution of the cross-sectional profile of the glass impingement angle and v-jet feed rate) on the kerf
channels generated by erosive wear in micro air geometry and its dimensional characteristics. [29].
abrasive jet machining using a round nozzle. R. Balasubramaniam et al (2002) Studied on the
Experiments were carried out on soda lime and shape of the surface generated by Abrasive jet
borosilicate glass to verify the process models. machining. They developed a semi empirical
Predicted model results show fairly good agreement equation to obtain the shape of Abrasive jet machined
with experimental results. [51]. surfaces, Effect of Various AJM input parameters on
N. S. Pawar et al (2013) presented Experimental the generation of shapes, deburred edge radius are
analysis of AJM with sea sand as abrasive material focused... [32].T Burzynski etal (2010) Presented The
and considering Silicon Carbide, mild steel as nozzle time-dependent evolution of an abrasive jet micro-
material with a vibrating cylindrical mixing chamber. machined surface and described by a partial
The experimentis conductedon glass sheet by varying differential equation which is difficult to solve using
the pressure &Sod. Graphs are plotted with variation traditional analytical or numerical techniques... [37].
in parameters. [57]. R. H. M. Jafar et al (2013) presented experimental
ANALYTICAL MODELLING data on the effect of particle size, velocity, and angle
Analytical modelling of Abrasive jet machining of attack on the Surface roughness of unmasked
involves the Study Investigations on Effect of channels machined in borosilicate glass using AJM.
different types of Process parameters on the Single impact experiments were conducted to
performance measures. This study highlights quantify the damage due to the individual alumina
different types of empirical equations, analysis of the particles. Based on these observations, the assumed
areas like surface roughness, impingement angle, location of lateral crack initiation in a relatively
variation in MRR, kerf geometry, etc., in which the simple analytical model from the literature was
AJM process can be effectively applied. modified, and used to predict the roughness and
Ingulli.C. N (1967) wasthe first Person Explained in erosion rate. [38].
detailed about Abrasive Jet Machining and Li et al (2008) investigated the process that combined
Highlighted Varies parameters effect on Material grinding with abrasive jet finishing, the material
Removal and Variation in MRR with change in removal rate (MRR) model in abrasive jet precision
Abrasive flow rate. [1]. finishes with grinding wheel as restraint was
Pandey, et al (1980) and Bhattacharya (1976) studied investigated. The material removal rate model was
the effects of abrasive flow rate {AFR) and standoff found to give a good description of the experimental
distance on the material removal rate (MRR). They results. [41]
observed that MRR reaches an optimum value with J. B. Byiringiro et al (2012) presented a novel
the increase in AFR and SOD, and then falls with the fabrication technique of a photo-resist mask onto 3D
increase in these parameters. [3]. curved wafer for micro-abrasive jet machining (AJM)
R. Balasubramaniam et al (1999) Explained process. In this study, the developed modelling
Deburring of cross-drilled holes by secondary algorithm for planar and non-planar mask models
erosion of an abrasive jet wasperformedand the assisted in two ways.Design. Optimization and
parameters effect on drilling were identified. [ 8]. significantly reduces the time required for
R. Balasubramaniam et al (2000) studied the experimental investigations. [46].
generation of edge radius by using the abrasive jet P. M. Khodke et al. Discussed about the work
external deburring... [9]. samples eroded by AJM shows that, for brittle
N. Jaganath et al (2012) combining abrasive and hot materials, material removal is due to an intersection
air to form an abrasive hot air jet. Abrasive hot air jet and propagation of cracks produced by adjacent
machining. The effect of air temperature on the impacting particles on the target surface. An
material removal rate applied to the process of glass analytical model d based on the above observations
Int J Adv Engg Tech/Vol.Electronic copy available at: https://ssrn.com/abstract=3682998
V/Issue II/April-June,2014/18-24
Srikanth et al., International Journal of Advanced Engineering Technology E-ISSN 0976-3945
for predicting the material removal in abrasive jet Taguchi method and analyzed that flexible magnetic
machining process. [49]. abrasive is adopted in abrasive jet machining. [53].
Slikkerveer et al. [1999] proposed an analytical Chang He Li et al (2006) In this Paper the Metal
model to predict the evolving cross sectional profile Removal Model is investigated in abrasive jet
of abrasive jet machined features. Their model relates precision finishing (AJPF) with the wheel as
the instantaneous surface slope to the local erosion restraint. In the study, the material removal rate
rate through the normal component of the particle model was established according to machining
velocity vector. The model was developed in brittle mechanisms and machining modes from two-body to
materials and assumes, therefore, that only the three-body process transition condition, and active
surface-normal velocity component contributes to number of particles in grinding zone were calculated
erosion [52]. and simulated. [54].
OPTIMIATION MODELING R. Balasubramaniam et al (1998) experimental
Modelling is a tool that is more capable of investigation has been conducted to identify the
Explaining the effect of various process parameters abrasive jet deburring process parameters and the
on the efficiency of Abrasive Jet cutting process. In edge quality of abrasive jet deburred components.
this review various authors are identified and Result of the edge quality measurements
established different Optimization models like supplemented with the visual inspection were
Simulation models, Idea diagrams, Taguchi etc. analyzed by the ANOVA method of Taguchi is used to
Alireza Moridi et al (2010) study presented on the designate deburring quality by employing the
micro-grooving of quartz crystals using an abrasive software STATGRAPHICS. [55].
air jet. Predictive models are then developed for U. D. Gulhane et al (2013)Conducted experiments
quantitatively estimating the machining performance. and Analyzed the influence of process parameters on
The models are finally verified by an experiment. MRR and Kerf width.The results of experiments are
[40]. Analyzed by Taguchi, Characterized the influence of
R. Haj Mohammad Jafar et al (2013)A numerical Factors on MRR and Kerf by Analysis of Variance
model was developed to simulate the brittle erosion (ANOVA) [56].
process leading to the creation of unmasked channels
as a function of particle size, velocity, dose, impact
angle and target material properties. Erosion was
simulated using models of two damage mechanisms:
The Experimental data are compared with the
simulated model and Analyzed. [43].
Alina Oancea et al (2012) The study of the solutions
corresponding to the sand blasting gun highlighted Fig-8-drilling of ceramic tile at diff pressure, sod, nozzle
some possibilities to modify the nozzle and the dia [56]
subsystem for clamping the nozzle. An ideas diagram HYDRID MODELLING
was used in order to identify some constructive In this section of the review the combination of
solutions able to satisfy the formulated objectives. unconventional machining processes like ECM,
Different Versions of Ideas diagrams are established EDM with AJM, Recycling of Abrasive particles,
and compared by using tables. [45]. micro grooving, masking etc. are discussed.
D Ciampini and M Papini (2010) A cellular V. K. Jain et al (2002) combined the performances of
automaton simulation for the prediction of the size AJM and ECM, termed a name ECSAD. Experiments
and shape of masked features resulting from the have been conducted using abrasive cutting tools,
abrasive jet micro-machining (AJM) of brittle targets with a view to enhance the capabilities of the process.
was presented. The simulation allowed the prediction [13].
of complex phenomena such as mask under-etch, V. S. Rajashekhar et al (2012) presented a paper on
mask ricochet, spatial hindering and second-strike reusing the Discarded Abrasive Particles from
effects, which cannot be readily modelled using Abrasive Water Jet Machining for Drilling Holes in
analytical techniques. [47]. Glass Sheet by Abrasive Jet Machining. The abrasive
A Ghobeity et al (2007) Models are presented to grains used in AWJM are reused and tested with
predict the shape and size of masked and unmasked AJM for drilling Glass. The process of Recycling can
holes machined in glass and polymethymethacrylate perform in two cases at Nozzle entry, exit and after
(PMMA) using abrasive jet micromachining (AJM). cutting in three recycling stages. [15].
The modified model predicts whole profiles that Alireza Moridi et al (2010) presented a study on the
agree well with both experiments and a computer micro-grooving of quartz crystals using an abrasive
simulation. [48] air jet. The effect of the various process on the major
Li, HZ (2012) presented an analysis of the AJM machining performance measures are analyzed to
Process for brittle materials. The analysis is based on provide a deep understanding of this micro-
a fundamental erosion model of the solid particle machining process. Predictive models are then
impact for brittle materials, and a recently developed developed for quantitatively estimating the
model for the particle velocity in micro-abrasive jet, machining performance. The models are finally
to form a mathematical basis for AJM process verified by an experiment. [22].
modelling and optimization. [50] M. Kantha Babu, O.V. Krishnaiah Chetty (2003)
Jiuan-Hung Ke et al (2012) presented a novel hybrid Discussed about the Recycling of Abrasive Particles
method that self-made magnetic, abrasive with with different sizes. Recycling leads to further
elasticity was utilized to investigate machining disintegration. The role of fine abrasives in reduction
characteristics in abrasive jet machining. They of cutting is well established. Hence recycling leads
Experimented with Magnetic abrasives and used to the decreased depth of cut. [26].
27. T Burzynski and M Papini1--Measurement of the NOZZLE FOR ABRASIVE JET ENGRAVING-
particle spatial and velocity distributions in micro- Nonconventional Technologies Review 2012
abrasive jets. ---Meas. Sci. Technol. 22 -2011. Romanian association of Nonconventional
28. D.S. Robinson Smart, 2011. Experimental Technologies Romania, June, 2012.
Investigation of Effect of Abrasive Jet Nozzle 46. J. B. Byiringiro, 1a T. J. Ko, 2H.C. Kim, 3 I.H. Lee,
Position and Angle on Coating Removal Rate. Fabrication of the photo-resist mask onto 3D
International Journal of Manufacturing Systems, 1: nonplanar wafer for micro abrasive jet machining,
57-64 2012 Mechanical Engineering Conference on
29. D.S. Srinivasu, D.A. Axinte, P.H. Shipway, J. Folkes, Sustainable Research and Innovation, Volume 4, 3rd-
2009. Influence of kinematic operating parameters on 4th May 2012.
kerf geometry in abrasive water jet machining of 47. D Ciampini and M Papini -2010-A cellular automata
silicon carbide ceramics. International Journal of and particle-tracking simulation of abrasive jet
Machine Tools and Manufacture, Vol 49, Issue 14, micromachining that accounts for particle spatial
1077-1088. hindering and second strikes-J. Micromech.
30. Shanmugam D. K., Masood S. H. 2009. An Microeng. 20 045025.
investigation of kerf characteristics in abrasive water 48. A Ghobeity1, H Getu2, M Papini1,2 and J K Spelt1,2--
jet cutting of layered composites, International Surface evolution models for abrasive jet
Journal of Material Processing Technology 209: pp micromachining of holes in glass and
3887–3893. polymethylmethacrylate (PMMA)J. Micromech.
31. Shanmugam D. K., Wang J., Liu H. 2008. Microeng. 17 2175-nov-2007.
Minimization of kerf tapers in abrasive water jet 49. P. M. Khodkea, d. J. Tidkeb & a. V. Ramaraoc. An
machining of alumina ceramics using a compensation Analytical Model for Material Removal in Abrasive
technique, International Journal of Machine Tools and Jet Machining for Brittle Materials. Materials and
Manufacture 48: pp 1527–1534. Manufacturing Processes Volume 11, Issue 4, 1996.
32. R Balasubramaniam, J Krishnan, N.Ramakrishnan… 50. Li.HZ, Process analysis of abrasive jet micro
Study on shape of surface generated in ajm - Journal machining for brittle materials [online] Australian
of materials …, 2002 – Elsevier journal of mechanical engineering Vol 10,No 1,2012
33. A Ghobeity1, H Getu2, M Papini1,2 and J K Spelt1,2-- :61-69.
Surface evolution models for abrasive jet 51. Stephen Wan, Weng Seng Fong, Qi Ying Leong--
micromachining Volume 264, Issues 3–4, 4 February Deterministic Process Modelling of Micro Air
2008, Pages 185–198 Elsevier. Abrasive Jet Machining of Glass Channel- 2010, Key
34. Y.L.HOU, X.Y.Ma,C.H.LiSurface microcosmic Engineering Materials, 447-448, 272.
morphology evaluation of finished by abrasive jet 52. P.J. Slikkerveer, F.H. in’t Veld, Model for patterned
with grinding wheel as restraint, CCDC'09 erosion, Wear 233–235 (1999) 377–386.
Proceedings of the 21st annual International 53. Jiuan-Hung Kea, Feng-Che Tsaia, Jung-Chou
conference on Chinese Control and Decision Hungb*, Biing-Hwa Yanc, Characteristics study of
Conference 2009. flexible magnetic abrasive in abrasive jet machining,
35. T Burzynski and M Papini1 -- Level set methods for 5th CIRP Conference on High Performance Cutting
the modelling of surface evolution in the abrasive jet 2012.
micromachining of features used in MEMS and micro 54. Chang He Li, Guang Qi Cai, Shi Chao Xiu, Q. Li ,
fluidic devices -Journal of Micromechanics and Micro Material Removal Model and Experimental
engineering Volume 20 Number 8-2010. Verification for Abrasive Jet Precision Finishing with
36. J-H Ke1F-C Tsai2,J-C Hung3,T-Y Yang1,B-H Wheel as Restraint.Key Engineering Materials
Yan1,*Fabrication of new composite abrasive for jet (Volumes 304 - 305)2006.
machining and application to scrap wafer 55. R. Balasubramaniam, J Krishnan, N.Ramakrishnan
regeneration. Journal of Process Mechanical Investigation on AJM deburring - Journal of Materials
Engineering, jan-2011. 1998 – Elsevier.
37. T Burzynski and M Papini1 - A level set methodology 56. U.D.Gulhani,P.P.Patkar,S.P.Patel,A.A.Patel et al
for predicting the effect of mask wear on surface ,Analysis of AJM Parameters on MRR,Kerf width of
evolution of features in abrasive jet micro-machining- Hard and Brittle Materials like ceramics,--IJDMT-
-Journal of Micromechanics and Micro April-2013
engineering Volume 22 -2012. 57. N.S.Pawar,R.R.Lakhe,R.L.Shrivastava-A comparative
38. R.H.M. Jafar*1, M. Papini2, 1, J.K. Spelt1, 2, Surface Experimental Analysis of Sea sand as an abrasive
roughness and erosion rate of abrasive jet micro- material using Silicon carbide and mild steel Nozzle
machined channels: Experiments and analytical in vibrating chamber of Abrasive Jet machining
model,-2013-Elsevier. process IJSRP Vol-3 issue-10,October-13.
39. Sagar, Ankur (2009) Mathematical Modelling Of 58. M. Chithiraipon selvan, Dr. N. Mohana sundara raju-
Abrasive Jet Machining For Metal Removal Rate On review on current state of research and development
Fiber Glass Using Abrasive Silicon Carbide. 30-Jul- of Awjc- international journal of advanced
2009. engineering sciences and technologies vol no. 11,
40. Alireza Moridi1,a, Jun Wang1,b, Yasser M. Ali1,c, issue no. 2, 267 – 275-(2011).
Philip Mathew1,c and Xiaoping Li2,d, A Study of
Abrasive Jet Micro-Grooving of Quartz Crystals Key
Engineering Materials Vol. 443 (2010) pp 645-651
Online available since 2010/Jun/02.
41. Li, C.H. Ding, Y.C.; Lu, B.H.Automation and
Logistics, 2008. ICAL 2008. IEEE International
Conference inSept. 2008.
42. Yan-cherng LIN 1, Yuan-feng CHEN 1, A-cheng
WANG 2, Wan-lin SEI 1-- Machining performance
on hybrid process of abrasive jet machining and
electrical discharge machining, Trans. Nonferrous
Met. Soc. China 22(2012) s775−s780-Elsevier.
43. R.H.M. Jafar*1, M. Papini2, 1, J.K. Spelt1, 2,
Numerical simulation of surface roughness and
erosion rate in abrasive jet micromachining of glass.
2013 – Elsevier.
44. Dong-Sam Park a,∗, Myeong-Woo Chob, Honghee
Lee b, Won-Seung Choc , Micro-grooving of glass
using micro-abrasive jet machining- Journal of
Materials Processing Technology 146 (2004) 234–
240.
45. Alina Oancea1, Lorelei Gherman2, Laurenţiu
Slătineanu3 and Vasile Braha4 -- MODIFIED
Int J Adv Engg Tech/Vol.Electronic copy available at: https://ssrn.com/abstract=3682998
V/Issue II/April-June,2014/18-24