Abrasive Jet Machining (AJM) : Material Removal

Abrasive Jet Machining (AJM)
• In AJM material removal occurs on account of impact of high velocity air / gas
stream of abrasive particles on the workpiece (WP).
• Abrasives are propelled at a high velocity by gas to erode material from WP.
• As an outcome of impact of the abrasive particles on WP, tiny brittle fractures
occur at the surface of WP and carrier gas carries away the fractured fragments.
• AJM is also called as abrasive blasting process. It is also known by several other
names such as abrasive micro-blasting, pencil blasting & micro-abrasive blasting.
• Effective method for hard and brittle materials such as glass, and tungsten.
• AJM is used for cutting intricate shapes or forms of specific edges.
• AJM is inherently free from chatter, vibration and heat problems because the tool
never touches the substrate.
High velocity abrasive jet (150-300 m/s)
Principle of AJM
The principle of AJM process is explained below:
1. Abrasive particles of size between 10µm to 50 µm are accelerated in a gas stream
(commonly air at high atmospheric pressures).
2. The smaller abrasive particles are useful for finishing and bigger are used for
cutting operations.
3. The abrasive particles are directed through the nozzle, towards the workpiece
surface where-ever cutting or finishing is to be done. The distance between the
tip of the nozzle and the work surface is normally within 1 mm.
4. As the abrasive particles impact the surface of the workpiece, it causes a small
fracture at the surface of the workpiece. The material erosion occurs by the
chipping action.
5. The erosion of material by chipping action is convenient in those materials that
are hard and brittle.
6. As the particles impact the surface of workpiece, it causes a small fracture and
wear, which is carried away by the gas along with the abrasive particles.
7. The abrasive particles once used, cannot be re-used as its shape changes partially
and the workpiece material is also clogged with the abrasive particles during
impingement and subsequent flushing by the carrier gas.
Equipment
Elements
• Gas propulsion system

• Abrasive feeder
• Abrasives
• Machining Chamber
• AJM Nozzle
1.Gas Propulsion System
• Supplies clean and dry gas.

• 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.
REQUIRED PROP OF GAS
Gas should be non-toxic, cheap, easily available.
It should not excessively spread when discharged from nozzle into
atmosphere.
Air, Nitrogen and carbon dioxide to propel the abrasive particles.
• The propellant consumption is of order of 0.008 m3/min
• at a nozzle pressure of 5 bar
• 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. ABRASIVES
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
Dolomite 200 mesh Etching and polishing
Etching and polishing 27 micros Cleaning, deburring and

cutting of soft material
4.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.
5. 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 criteria
Abrasives Carrier Gas
material – Al2O3, SiC, Crushed Composition-Air, CO2, N2

glass, Sodium bi carbonate
Density=1.3 kg/m3
shape – irregular/regular
Velocity-500 to 700 m/s
Size – 10 to 50 microns
Pressure-2 to 10 bar
Mass flow – 2-20 gm/min
Abrasive Jet Nozzle
Velocity - 100 to 300 m/s Material – WC/Sapphire

Mixing ratio – Volume flow rate of
abrasives/Volume flow rate of gas Diameter – 0.2 to 0.8 mm
Stand off distance – SOD- 0.5 to 15mm Life – 300 hours for sapphire,
20 to 30 hours for WC
Impingement angle – 60 to 90 deg.
Process capability
• Material removal rate – 0.015 cm3/min
•
• Narrow slots – 0.12 to 0.25mm ± 0.12mm
• Surface finish -0.25 micron to 1.25 micron
• Sharp radius up to 0.2mm is possible
• steel up to 1.5mm ,Glass up to 6.3mm is possible to cut
• Machining of thin sectioned hard and brittle materials is

possible.
Applications
 Drilling holes, cutting slots, cleaning hard surfaces, deburring,
polishing .
 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.
AJM: Advantages
Advantages of AJM:
o For machining fragile, brittle and heat sensitive materials
o Localized forces and less heat generation than the
conventional machining processes.
o No tool-workpiece contact, hence lesser force and heat
generation.
o There is no damage to the workpiece surface.
o High flexibility.
o Low power consumption.
AJM: Disadvantages
Disadvantages of AJM:
The process is limited to brittle and hard materials
High nozzle wear rate
Low MRR
The process results in poor machining accuracy
The process can cause environmental pollution
Silica dust may be a health hazard.
Material Removal Rate
 Material or Volumetric Removal Rate (MRR or VRR) is given by
the formula
Machining characteristics
• Effect of abrasive flow rate and grain

size on MRR
Efect of Mixing ratio on
MRR
Effect of Nozzle
pressure on MRR
Stand off distance.

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Abrasive Jet Machining (AJM)

• Gas propulsion system

• Supplies clean and dry gas.

• Required quantity of abrasive particles is supplied by abrasive

Abrasives Grain Sizes Application

Aluminum oxide(Al2O3) 12, 20, 50 microns Good for cleaning,

Silicon carbide (SiC) 25,40 micron Used for similar

Etching and polishing 27 micros Cleaning, deburring and

• It is well closed so that concentration of

• 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

With increase in wear of a nozzle, the divergence of jet stream

material – Al2O3, SiC, Crushed Composition-Air, CO2, N2

Abrasive Jet Nozzle

Velocity - 100 to 300 m/s Material – WC/Sapphire

• Surface finish -0.25 micron to 1.25 micron

• Sharp radius up to 0.2mm is possible

• steel up to 1.5mm ,Glass up to 6.3mm is possible to cut

• Machining of thin sectioned hard and brittle materials is

• Effect of abrasive flow rate and grain

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