International Journal of Management (IJM) Volume 11, Issue 5, May 2020, pp. 2146-2152, Article ID: IJM_11_05_213 Available online at https://iaeme.com/Home/issue/IJM?Volume=11&Issue=5 ISSN Print: 0976-6502 and ISSN Online: 0976-6510 DOI: https://doi.org/10.34218/IJM.11.5.2020.213 © IAEME Publication Scopus Indexed EFFECT OF PARAMETERS OF ABRASIVE JET MACHINE ON DIFFERENT MATERIAL Haseeb Ahmad khan, Sarthak Sharma and Bhaskar Chandra Kandpal Department of Mechanical Engineering Inderprastha Engineering College, Ghaziabad, U.P., India Nitin Johri Department of Mechanical Engineering, Graphic Era Deemed to be University, Dehradun, U.K., India ABSTRACT Abrasive jet machining is a metal removal process involving erosion of work surface on account of impingement of stream of high speed abrasive particles through a nozzle by high pressure air or gas. The small bits of work surface material get loosened due to repeated impacts and get loosened thereby being carried away by jet of abrasive particles. This paper reviews various parameters of abrasive jet machining and their respective effect on different materials. Key words: Abrasive Jet Machining (AJM); Material Removal Rate (MRR); Penetration Rate (PR); Stand-off distance (SOD). Cite this Article: Haseeb Ahmad Khan, Sarthak Sharma, Bhaskar Chandra Kandpal and Nitin Johri, Effect of Parameters of Abrasive Jet Machine on Different Material, International Journal of Management (IJM), 11(5), 2020, pp. 2146-2152. https://iaeme.com/Home/issue/IJM?Volume=11&Issue=5 1. INTRODUCTION As there is a development in the industry of science and technology, there is a significant demand for higher efficiency and good quality of machining. Abrasive Jet Machining (AJM) is one of the most used non conventional processes. It is also known as Micro-Abrasive Blasting. This process used to erode the material from the surface of the work piece, In this abrasive particles mixed with the high pressure compressed air accelerated through a nozzle of very small diameter, the potential energy of fluid is converted to kinetic energy, this high velocity fluid stream are triggered on a surface of a work piece which helps to remove the material from the work piece. This results in removal or erosion of material known as material removal rate (MRR). A number of researches are carried out to study the (MRR) by changing the parameters of AJM. These parameters on which basis the MRR is based can be defined as the work piece material, Abrasive used, Nozzle diameter, Jet velocity, Incidence angle, penetration rate, stand-off distance and many more. https://iaeme.com/Home/journal/IJM 2146 editor@iaeme.com Haseeb Ahmad Khan, Sarthak Sharma, Bhaskar Chandra Kandpal and Nitin Johri In a study that the removal of material from Ductile material may result in plastic deformation and fracture to the work piece [1], In another study when high velocity particles targeted on the surface of material which makes a deformation wear causes break and crack of the work piece result in material removal. [2].The MRR mostly depends on the type of work piece material [1][3] and the parameters used. The AJM process may result in plastic deformation in Ductile materials whereas for Brittle materials no plastic deformation (Fig.1.). Figure 1 Abrasive material removing for (a) Ductile materials, (b) Brittle materials [4] An abrasive (AL2O3, SiC) also plays an important role in AJM as abrasive can be used in Blast cleaning Application. In blast cleaning particles of abrasive are targeted with jet air at a coated or contaminated layer and the layer is removed by mechanical means of abrasive impinging. For example, the paint stripping of aircraft [5]. AJM is leading behind the most widely used processes such as facing, cutting, milling, surfacing which are not very economical to use due to the lot of waste material produced as MRR is very high is such a process. So to manage the MRR, the nozzle dia and incident angle of nozzle are also important. Thus this paper has a detailed study about the different parameters which can be used by AJM. 2. EQUIPMENTS REQUIRED 2.1. Carrier gas In an abrasive jet machining, a jet is produced by mixing the gas with abrasive particles. The gas used is called carrier gas. Some of the most common carrier gases employed are air, carbon dioxide and nitrogen. These gases are eco friendly and easily available. But Oxygen is never used as a carrier gas as it may oxidize the surface of the work piece. [8] 2.2 Abrasives These are responsible for the removal of material from the work piece. Abrasive particles/grains should be of sharp and of irregular size for good cutting property and also have good flow property. As the particles/grains of the abrasive strikes on the surface of the work piece with high pressure and high velocity which result in removal of material from the work piece [6]. Some of the abrasives commonly in use are as follows: (a) Aluminium Oxide (Al2O3) (b) Silicon Carbide (SiC) (c) Glass beads (d) Crushed glass (e) Sodium bicarbonate https://iaeme.com/Home/journal/IJM 2147 editor@iaeme.com Effect of Parameters of Abrasive Jet Machine on Different Material These are some of the abrasives used in AJM. Selection of abrasives depends on MRR, type of work material, and machining accuracy as shown in Table 1. Table 1 Abrasive types with respect to grain sizes and applications [7] Abrasive Grain size Application Aluminium oxide (Al2O3) Silicon carbide (SiC) beads Glass Sodium bicarbonate 12, 20, 50 microns 25, 40 microns micr to 1.27 mm 0.635 200 mesh Good for cleaning, cutting and deburring Used for similar applications but for hard materials Gives matte finish Cleaning, deburring an cutting of soft material. Light finish in below 500°C. Dolomite 27 microns Etching and polishing 2.3. Work piece material Generally, the AJM process is used for hard, brittle materials and glass sheet materials, As the brittle materials do not have any deformation and good cutting can be performed on it whereas in case of ductile materials, plastic deformation, cutting wear, plastic strain, and deformation wear occurs which leads to decrease in MRR. Thus we can say that ductile materials are not usually preferred to use for AJM processes most widely brittle materials are used in AJM, such as Ceramics, glass etc. (Fig. 2). Figure 2 Process of AJM 3. APPLICATIONS AJM has a wide application in the present scenario where there is a need for a less waste product. AJM results in less MRR which makes it very economical and good for the industrial purpose. Some applications of AJM are as follows. https://iaeme.com/Home/journal/IJM 2148 editor@iaeme.com Haseeb Ahmad Khan, Sarthak Sharma, Bhaskar Chandra Kandpal and Nitin Johri 3.1. Micro-sand/Abrasive Blasting The principle of micro-abrasive blasting is to accelerate the sand particles to make the surface clean, engraving on the surface of the material [7]. Used for ceramics, quartz, glass, sapphire, mica etc (hard and brittle materials). 3.2. Precise Drilling/Cutting and removal of parting line of casting This application of AJM uses where very precise and accurate holes and cuttings are required. Also helps in cleaning the parting lines which are caused by the casting process This is very flexible to use in small pipes, small semiconductor devices. 3.3. High quality surface finish and frosting the glass This can be used in finishing and cleaning action of low strength material such as Teflon, Nylon, Plastic and also frosting the glass surfaces. 4. PROCESS PARAMETERS Process Parameters are the parameters which should be determined while working on AJM. It is necessary to analyze the following process parameters to obtain the desired results on AJM. Some of them are given below. (Table 2) 4.1. Material removal rate (MRR) It is one of the most important parameter used in AJM. As this parameter describes efficiency the AJM, As it is the volume of material removed from a given work piece in per unit of time. 4.2 Geometry and surface finish of work piece The geometry and surface finish plays an important role in MRR, to have good MRR then fine grains should used to get the good surface finish 4.3. Wear rate of the nozzle With increased abrasive pressure there is wear in the nozzle and the divergence of jet stream increases resulting in more stray cutting and high inaccuracy. 4.4. Abrasive mass flow rate Mass flow rate of Abrasive impacts the MRR in AJM. In this mass flow rate of air contrairly corresponds to the mass flow rate of Abrasive particles. With increasing the abrasive mass flow rate, first MRR increases to ideal worth and then decreases. 4.5. Stand-off distance (SOD) It is the gap provided between the nozzle tip and the workpiece so that there is a proper striking of the abrasive on the workpiece If the gap is small then the abrasive will penetrate the workpiece and if there is a large gap then flaring generation on the workpiece which could damage the work piece. 4.6. Gas Pressure Air or gas pressure has a direct impact on metal removal rate. In AJM, metal removal rate is directly proportional to air or gas pressure. As the pressure increases the depth of cut also increases. https://iaeme.com/Home/journal/IJM 2149 editor@iaeme.com Effect of Parameters of Abrasive Jet Machine on Different Material 4.7. Jet Velocity It is the velocity of the Abrasive particle at which they strike the surface of the workpiece. MRR increases with increase in velocity of abrasive particles. 4.8. Mixing ratio It is the ratio which determines the quality of Air and Abrasive material in AJM. When mixing ratio is increased continuously, metal removal rate first increases to some extent and then decreases. 4.9. Abrasive grain size Abrasive grain size is important in parameters as large, coarse and fine grains are used in cutting and surface cleaning actions. As small grains will provide small cutting and also can bind together and can block the nozzle of AJM. Generally the grain should be between 10 micron to 50 micron. Table 2. Process criteria which are influenced by the process parameters Carrier gas composition Abrasive Jet velocity Abrasive flow rate SOD Nozzle Nozzle life Pressure AIR, CO2, N SiC and Al2O3 Size- 10 to 50 microns. Shaperegular 150 to 300 m/s and irregular 2 to 20gm/min 2 to 15 mm ( 8mm ideal) WC /sapphire Diameter- 0.18 to 1mm Sapphire-300 hours 30bars hours 2WCto 10 5. CONSTRUCTION FOR AJM • • • • • • • • • Compressor Pressure gauge Air Filter Hopper Mixing chamber Nozzle holder Nozzle Work piece Working Space/box 6. ADVANTAGE Some of the advantage of AJM are as follows :(a) It can cut brittle material of any hardness with accuracy. (b) No heat generation occurs while cutting the material. Thus this result in no change in microstructure of the material. (c) The setup of AJM requires low investment and also less consumption of capital. (d) There's a Stand off distance between the workpiece and tool, so the tool does not wear when it comes in contact with the workpiece. (e) Good surface finish can be obtain by using fine Abrasives. https://iaeme.com/Home/journal/IJM 2150 editor@iaeme.com Haseeb Ahmad Khan, Sarthak Sharma, Bhaskar Chandra Kandpal and Nitin Johri (f) There is no need for coolant as carrier gas acts as a coolant. 7. DISADVANTAGES (a) Minimum pressure should be maintained for the cutting action of the abrasives (b) Work piece used should have good surface finish, No roughness on the surface. (c) It is a time consuming process as It has a low MRR of about 14mm3/min. (d) Proper abrasive should be used for the soft materials such as plastics (e) Hopper and mixing chamber should be free of any moisture content as moisture could choke the nozzle. (f) As abrasives flow with high pressure which can result in wear of the nozzle. 8. CONCLUSION Abrasive jet machining is a metal removal process involving erosion of work surface on account of impingement of stream of high speed abrasive particles through a nozzle by high pressure air or gas. The small bits of work surface material get loosened due to repeated impacts and get loosened thereby being carried away by jet of abrasive particles. This paper reviews various parameters of abrasive jet machining and their respective effect on different materials. These find application in following areas. • Super alloy machining and machining of refractory materials • Drilling and contouring operations • Cutting of thin sections and slots • Deburring and shallow crevice production • Glass tube internal surface frosting • Polishing and cleaning of nylon, plastic and teflon component • Intricate hole production in brittle material etc REFERENCES [1] Sheldon, G. L., & Finnie, I. (1966). On the ductile behavior of nominally brittle materials during erosive cutting. Journal of Manufacturing Science and Engineering, Transactions of the ASME, 88(4), 387–392. https://doi.org/10.1115/1.3672666 [2] Wakuda, M., Yamauchi, Y., & Kanzaki, S. (2002). Effect of workpiece properties on machinability in abrasive jet machining of ceramic materials. Precision Engineering, 26(2), 193–198. https://doi.org/10.1016/S0141-6359(01)00114-3 [3] Evans, A. G., & Wilshaw, T. R. (1976). Quasi-static solid particle damage in brittle solids-I. 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