ArticlePDF Available

A review of abrasive jet machining

Authors:
  • Retd. P&HVidya Academy of Science & Technology

Abstract

Abrasive jet machining is one of the unconventional machining processes which, using various operations such as deburring, polishing, cutting etc., can be carried out effectively and efficiently, to close tolerances. In this paper, a comprehensive review of work done in this field is given and complex analytical findings that have been made are highlighted. The considerable scope for research and the implementing of it for commercial purposes are also pointed out.
c\l
FI
o\
ro
r-r
c{
0)
a
x.Y
;>
?@
N
I
d.
F
z
- o:
!l
en
a
a4.
6
a'!
a
.l
a
d.
q)
al
d
F+
UO
cD
t*
q)
q)
{
R
t*
TJ
N
(.)
E
0)
.d
F
o
a-l
d!
AA
YA
+) ;a
Atl
'l +)
H .FI
Ri
A
dvc)
od
N::
N7
AH
z;
ii
ai a' tr
v 6\
.^-
l.
.=ix
.J- F :I
v!
s
q)
AJ
c/)
L
o
a
q)
L
N
L
rr
N
R
e
d
+)
-
E
+J
Fr
bo
a-
t-{
ho
a4
liE,l
rJ F-
AO
cgi
c>
A-
'!1 tr
-vo
lla
FEB
ztu
..>
Aqo
6P
AJ CJ
r-l
I
r-l
c\
Fi
i
F
Fq)
SU0
a
C/l
L
C,)
L
\
a
N}{
€0)
t*>
l;
NF
r-l
61
--
bqlt
q
o.c
-E
o
E
OF
c
E
qt
E
F
o
ooo
OOGI
ro or
Eg
a. a,
coO
(vt c)
oc
:E
"
E
F
o
ooo
TI:
ooo
o
N
*/n
E
E
?
o
E
E
aO
;
* ^^ ' rapul rEafl\
* A\'rtpul ,ean
'xapur Jealv\
EE
:i
(\F
\t \t
o@
O€
ro@
ro (\,
9c
:E
"
E
oF
T:
oo
r l'rapul ,!an
oo
oN
oo
ooo
TT:
OCro
*/\A'rapu! reaAl
tr-
6n
|Jr
sl
a,
L
c'l
c,
o-o
G'
c/l
c
(o
9>
(!
o.
(,r)
o()
.!,
-rt
E
E
s,
al!
E
q,
al
t!
@€o
;-i
o
E
E
.9
bnc
.S t,
"cu
c-i o
c3t
FJ
(')
q) +
v
C/)
L
a)
AJ
L
{
t*
\3
N
t
\t@
€r
(n
o
oo
\|
f
ul
-q,
{
E
{.
o
\t
o
(t)
!l
N
|,l
(,
(
urur
16ut
1
ale.r lenouJal
lelJalen
( urui / 6ur
)
alel le^Ourtr lelitleH
( urur
I 6u.r
I
aler leAouraJ
lerJaley{
1uru76ul
1
aleJ le^ouJar te'ralell
E
|'n
cO
o
@
ql
N
'6
orE
frn
@
o-c
>ul
O!,
EE
Po
t@
o..
LGI
q,N
ot,
E-
9L)
a,
N
3'6
=
or
\,
o.-
@o
(0
Il
!l
o
E-
1t!
EO
.gE
CG'
SE
(!L
!|
fo
!n
EE
E
1{ r.
|n0 co
(\rrt jl-
lP
:
bO
AJ
C/)
q)
p
H
N
e
g-01 x fas/ur
alej uotleJlzuad
11-01
x ras lEw
'DIe)' u./aJ
.leuJ
,loA
E
E
U
u
c
(!
.g
D
o
I
E
c
r0
r/)
t;
:
o
E
E
!,
u
c
o
u)
D
o
I
E
c
r!
rn
l-
t:
:
oo
{
o
tO
U
(J
c
o
U}
D
o
I
o
c
o
(n
t9
!
@
{
R 3P
6\ H
v.i
(1 4
H
O.F
.-l -
trv
Ad
i/:
VJF
q+r
A+)
a\
a\'-
r- U
S h.i
.sd|d)
eAd
!sw
': Li tr
\A
E f d
E
s xq)
H Y,4
.x, i +)
R a g
'= 'rl 'F
F€X
v
-o :>
<Jcoo
h COF
--
a d I
H -
aD a{
rv_
3Cfrl
SD N,:
L'
.H -
I F*
elv
d
p = H
H
: dH
, v
i ic)
- .i:H
ts#/
!V-
.S oo
\U
a hP
-v -i
Oel-
^-
=
:
a
-\
o\
d\
€o i
A-
LV
'iT
im/
!v- /
>g
o .,J
F-l
v.;
-q
cgr
'i>
RZ
;v
F
c+i >;
cFi
!
a -.
trs
Ekl
J-r
3$
,4<
Fca
C)\
.-
E")
giL
cFl
C0 r,
c,t
$
=
as
a33 n
- .v.v \.4
COrara a
I *: i'f
Ec<J-
n, -qJ -aD Q)
=+'+ C)
'--- cd
:- ^
Y '--r oJ 5-!
4PPr^
- -
cH d a.{ (H
^^'-^.' ^
oOOtr
fF.,{dh
(3-r.;.;a4
^\Hrt7X-
r- 'r \J \J 'rl
Fd..d
>.-Yih.-:
rl
.O
O)O-1Cl
co:f<js
@
:1 cO $ TOCOC=CCOC-1I-- u1 = tr-:C O)O r-r Nct $ tC @ \
- J=l-'-rNonNNli ri :: rlil c\tco ca cocc .6 ca cQ co
a
lr
C)
:-o
)
= A.
cd-
xo8
HE
€.9
tro
9a
a/
0.) c.)
E'F
oq)
r\ A
v ;;i
*H
$-r \s
-a 'S
lv:
rs
0)
*{ F.r
9S
qlI
n\
v
,tll C S
j5 coR-
s 5&
All\O
sr=s.Z
(.)d.:v
t7t /./. F
Y-i
U
E Z S
\
()o'
F{:
o!
tiS
:.
(,) R
(-'! u'
-A
r\
F
co
I
v
s
s>|
bo
-
(J
C)
F
bo
q
a
(-)
lr
a
d
H
q)
l-r
&
rYl
rrf
V)
J
rI]
a=F
>,
bo
()
c)
0.)
(J
!
a
a
o
()
c)
U
b0
cd
o€
'
ibi'
Cs ! L
f U J I
Lau o
o
o,:
c
d
o.-
AO
l,>
6f,
LOF
;a\
l.
ca
I
\t'
q
a\
\
\tA
A
F:
V)
q
q)
t
V)
t
q)
\
o'
L.
\
q)
CJ
h
I
\
o\
o\
\
\
-s)
t:
4
U)
q)
L
V)
F*
q)
R
e
o'
L.
A
\
R
a.)
r\
R
u
o
6
U
D
>!
!uo
)
OC
o6i
c€2
-ca
Oo
-,9 !
@: ;
o
o
6r
c
Fr
zi
o
6
o
o
o
o
L)
6
o
-6E
>o
60
Ca
E
o
a
.A
I
\
a\
o\
\
\
6
A
Fr
a)
q)
l*
v)
L.
q)
o'
R
L
q)
L.
ts
o
E
sl
6L
Fo"
h
I
\
o\
a\
\t.
\h
-
.q)
F\
q
v)
\)
L
4
L
q)
R
\
o'
r.
a,)
\
iS
a
E
E
N
I
o
ot
6
u
6
3r
z
oo9o
zrdFId
HITJUZ^
z L r{ < qr J
< &|, vl
ui
A (F. i
4 <H i
< =X^l
:} ' d Id 4i
UOQ Xt tL
O J I& C >l
r r v J E:
AI
QU:
u<l
<=:
= Id^ :
tdlod
oQHE :,^
H)V')
v)LJ9
x
J
z
H
FZ
!lH
4F
H<
ol
v
zh
tr
:
oa
I
\
o\
a\
\
\
Q
rQJ
t\r
v)
q)
q)
l*
j3X
'F#'
q)
L.
\
q)
N
l*
R
R
r:
UI
az;
Q d< |
il <v I
< =h
' YZ^:
v :} u td tri
uo< ci
o
<JOgll
a r. ,, A 6i
/9
UJ
a
t
>'
O
bo
'J
C)
bI)
c)
bo
-
l-r
0.)
0
o
a
H
k
o
a
a
U
sbo
It
0
Jctl
L
c)
a
ao
L
L
st
(D
fF
o
qt
o
(!
6
o
oo
c
,
I
:l
b
d
o
a
L:
E!
UO
I
\
a\
\f.
\I
-
Q
f\
4
q
t
N
L
\
N
-
\s
-
\
:
z
-q:
C)7
trO
a)bo
Li (-
ts l-r
OE
FE
o
a'l
.o bo
xc)
6'o
c.)
q)
* c.)
-()
oo€
(-1
.F oIJ
-o .:
C)
vY
xa.
6)
ar-
x a.)
x
^'()
qr -q)
.h tF
<l c)
X()
Y
ac)
Tl
't (-
I
\
o\
\
\>,
-
Q
rQJ
t\
q
q
U
-
A)
s
L.
N
\
o'
N
L-
e
\
N
s
L
\s
=
z
ol,
I
\
a\
\
\
-
S
'-
?
7
... In other words, it's the instantaneous MRR at which a speci ied cross-sectional area of material being removed as it moves through the workpiece [11]. Several research has been carried out to study the MRR in AWJM [4,12,13,14,15,16,17,18,19]. The behavior of machined material vigorously depends on the optimum/maximum process parameter especially lowrate of abrasive being used. ...
... Researches by Hutchings [17] describe the rupture is the result of lip detachment and Kovacevic [4] investigated that the material removal of ductile materials is mainly caused by platelet mechanism. Ramachandran [18] researched that in AWJM many more parameters can be de ined since much of analytical work is yet to be conducted on the effects of particle distribution in AWJM mixture stream and particle combination. Simultaneously, several researchers have researched to investigate and explain the material removal due to the erosive action of AWJM for different materials [12,13,14,15,16,17]. ...
Article
Full-text available
Waterjet machining is one of the emerging technology for machining hard materials that are very hard to machine by traditional machining processes. A high-velocity jet of water with abrasive particles gives eco-friendly and rel�atively economical machining options for cutting, which make leading machining technology in a short span. This paper reviews the work from the start to the development of waterjet machining within the past two decades. The work also points toward the improvement of performance regarding control and monitoring of different machining parameter i-e material removing rate, standoff distance, traverse speed, kerf width & surface roughness.
... The most enticing modern machining process for eroding brittle materials and hard surfaces is air abrasive jet machining (AAJM) [29,30]. The AAJM technique is known for its low power usage and modest capital investment. ...
... Air abrasive jet machining (AAJM) is one of the most alluring unconventional machining techniques for degrading non-conductive materials with hard surfaces and brittle materials [20][21][22]. It has less thermal and mechanical residual stresses generated during machining. ...
Article
Nowadays, bio-ceramic composite material is demanded in the biomedical industry due to its remarkable biological and mechanical properties. But, the shaping of such material challenges the manufacturer. In this work, bioceramic composite materials, having general weight composition [(100-x) (3Y-TZP) – x (13-93 BG)] where x = 0 to 25 wt%, has been prepared, and their machinability in terms of MRR (material removal rate) and SR (surface roughness) is studied as a function of BG composition and machining temperature. It is found that MRR decreases with increasing the concentration of bioactive glass (BG) while it increases with increasing the machining temperature. The SR is found in the opposite trend. The MRR, SR, and material removal mechanics (MRM) are also confirmed by the HR-SEM and AFM (atomic force microscopy) analysis. The effect of BG addition on the physical, mechanical, in-vitro degradation, and cell culture behaviour of the composite materials are also evaluated. The relative density and mechanical properties, such as flexural and compressive strength, are found to increase up to 10 wt% of BG content; afterward, it decreases. The hardness is increased with BG addition in 3Y-TZP ceramics. The in-vitro degradation indicates the dissolution and apatite layer formation after 35 days of immersion in simulated body fluid (SBF) solution. The cell proliferation is examined by MTT assay over MG-63 cell lines. The cell proliferation ability of the composite is increased with increasing the BG concentration and found a maximum of up to 25 wt% of BG. Overall, the best findings were obtained with 10 wt% BG contained 3Y-TZP ceramic composite sintered at 1250 °C. The relative density, flexural strength, and compressive strength are about 98.34%, 397.9 MPa, and 488.7 MPa, respectively. Based on the obtained results, it may be recommended that 10 wt% BG concentration in 3Y-TZP bioceramic composite is the most suitable and potential material for biomedical application.
... During AWJM more than 25 input parameters were identified by the researchers [6]. Major input parameters which affect the cutting performance of the AWJM process are water supply pressure (WP), nozzle diameter, stand-off distance (SOD), size and type of abrasive particles nozzle transverse speed (NTS) and abrasive particle flow rate (AFR) [7]. ...
Chapter
Full-text available
Abrasive water jet machining (AWJM) is a non-traditional technology widely used in industries for processing of materials. AWJM is a replacement for the other modern and conventional machining processes that have thermal or mechanical disadvantages for workpiece and tool material. AWJM is mainly used for cutting but few researchers successfully used AWJM process for controlled depth milling, drilling, turning, peening etc. Today's modern technology developed the AWJM process into a complete machining process that can produce precise and consistent results. AWJM can easily be employed for processing of intricate shape components made of brittle, hard, soft as well as ductile materials. A wide variety of materials ranging from stone, glass, titanium, steel, ceramics, composites, etc. can be easily machined by the AWJM.
... In order to overcome the defects of traditional polishing, it is necessary to seek a flexible and compliant polishing process that can continuously gather the abrasive particles in the polishing area for a long time. People have begun to study and use non-traditional polishing methods to achieve a constant material removal rate, including laser polishing [11,12], ultrasonic polishing [13][14][15], electrochemical polishing [16][17][18], solid jet polishing [19][20][21][22][23], liquid suspension polishing [24,25], etc. ...
Article
Full-text available
Electrorheological (ER) polishing, as a new ultra-precision super-effect polishing method, provides little damage to the workpiece surface and is suitable for polishing all kinds of small and complex curved surface workpieces. In this paper, an ER polishing tool with an annular integrated electrode is developed. The orthogonal experiments are carried out on the six influencing factors of ER polishing which include the applied voltage, the abrasive particle size, the abrasive concentration, the polishing gap, the polishing time and the tool spindle speed. The influence order of these six factors on the ER polishing is obtained. On this basis, the effect of a single process parameter of ER polishing on surface roughness is studied experimentally.
... For example, during the manufacturing of SiC, the carbon monoxide released which acts as a pollutant. Ramachandran et al. [8] identified various applications where MRR plays crucial role. In general, optical and toughened glass can be easily machined using AJM process. ...
Article
Full-text available
Abrasive Jet Machining (AJM) process is one of the unconventional machining process used to cut various materials including soft and hard materials. Alumina and silica are majorly used as abrasive materials due to its chemical and abrasion resistance. In this paper, abandoned Ceramic Sanitary Ware (CSW) wastes are used as abrasive materials in AJM process. Since, CSW wastes contain major amount of alumina and silica compositions. Initially, ball milling machining process is carried out to convert CSW wastes into micro particles. Then, sieving is performed to segregate the particles with its size. Stand of distance, pressure and particle size are considered as most influencing parameters in AJM process. Hence, Full Factorial design is utilized for three process parameters and three levels. The nozzle with a mixing chamber is designed and fabricated to perform drilling operation in the glass work piece. L27 experiments are carried out to evaluate Material Removal Rate (MRR) and Hole Diameter (HD) during drilling process of glass work piece. Further, the effect of each process parameters on MRR and HD is validated. From the analysis, it is found that pressure is most influencing parameters affecting MRR whereas HD greatly depends on particle size.
Book
Additive Manufacturing of Biopolymers: Materials, Printing Techniques, and Applications describes various biopolymers that are currently used in additive manufacturing technologies and identifies the challenges/limitations in the materials and printing processes. The book provides basic knowledge and advanced details about 3D printing techniques and the applicable biopolymers as well as the latest updates on materials and techniques for 3D printing of biopolymers. Each chapter dedicates a section to future trends and perspectives in additive manufacturing of biopolymers from the use of biopolymers and new techniques point-of-view.
Article
In the past few decades, sophisticated machining industries have rapidly improved in order to achieve the required shape of a part within a specific time while also not affecting material properties. Accuracy of machined components in all industries is important. In the case of subassemblies of components, geometrical accuracy of hole is vital. The researchers updated their machinery from time to time from this perspective. In the machining process, environment and time are the vital parameters that are mainly affected, so in this case, the design of experiments that are very useful in the machining region needs to be considered to overcome these challenges. This study aims to analyze the fabrication of hot abrasive jet machining (HAJMing) with different abrasive temperatures using fluidized bed system as well as accomplishment of cutting performance in hot-abrasive jet machining concerning target surface erosion. Additionally, this research study accomplishes the experimental study and computational fluid dynamics (CFD) technique for erosive footprint prediction extent in HAJMing constraints on target surface for intricately shaped tapered holes generation. The use of hot abrasives in the HAJM process has demonstrated an interest in improving cutting performance for material erosion. Moreover, this proposed experimental work contains the manufacturing, design and fabrication of hot abrasive jet machine (HAJM) using commercially available hardware and software. So, the components are manufactured indigenously as per the designed parameters for the purpose of improving the machining performance. Simulation for material erosion mechanism of HAJMing is used to obtain the nature of produced workpiece profile. Additionally, FB-HAJMing also deals with the sustainability assessment under environmental-friendly hot abrasive-assisted machining conditions.
Article
The effects of machining fluids on the finishing characteristics are clarified experimentally. The effects on the stock removal and the surface roughness are shown. The stock removal increases almost linearly with finishing time. The stock removal in the application of 5 wt. % light oil, emulsion type grinding fluid and straight oil type grinding fluid was larger than that without machining fluid.
Article
The principal types of wear involve adhesion, abrasion, corrosion, surface fatigue and gross fracture. Practical wear situations rarely involve only one of these and the different types of wear frequently interact. Adhesive and abrasive wear are of the greatest importance in mechanical systems and are discussed in detail. Means for reducing mechanical wear are considered.
Article
A study was made of the magnetic abrasive finishing process including the finishing mechanism and the finishing characteristics when using different types of magnetic abrasives. Some of the results are presented which show how the different types of abrasives and their grain affect stock removal and finished surface roughness.
Article
This report explains the process principle, the method; and confirms experimentally in a model test that the magnetic abrasive brush supplies enough pressure corresponding to the strength of the magnetic field to finish the work surface.
Article
This paper reports on a new finishing process in which a plane workpiece is machined by using a magnetic-abrasive particles in a magnetic field. The experimental plane finishing device and the experimentally determined effects of various working factors on the finishing characteristics are described.
Article
Using the electrolytic-abrasive mirror finishing method, a large area of stainless and ordinary carbon steel workpieces can be mirror-finished in a short time and with high efficiency up to a surface roughness of 0. 01-0. 02 mu mRmax. This method is based on the fact that the electrolytic effect is assisted by the polishing action of abrasive grains within an appropriate current density range by using neutral salt type electrolytes. Based on the previously derived theoretical equation and results of processing experiment under complex electrolytic and abrasive finishing condition, the authors derived a practical equation of processing that can be applicable to mirror finishing of a large area in production scale.
Article
The article describes the electrolytic-abrasive mirror finishing method which, by using loose abrasive mixed with the electrolyte, enables the surface of austenite stainless steel to be finished to a maximum roughness of 0. 002 mu m in a short time.
Article
A survey is presented of the experimental work which has been carried out on the abrasive wear of metals. The effect of variables such as surface hardness, abrasive hardness, abrasive particle size, and velocity are discussed for several types of abrasive wear. The similarities between different types of wear are described with the viewpoint of using one type of wear test to rank materials for another application.
Article
This paper describes a new spindle-finish type finishing apparatus and the finishing performance it provides when using magnetic abrasives of 0.15 mm in diameter in a magnetic field. The features of this maching process are : the finishing process is carried out with the application of magnetic force instead of the centrifugal force of finishing media in the conventional barrel-finishing process ; the finishing force of the magnetic abrasives is controlled by exciting current of a magnetic coil ; and surface finishing, deburring, and precision rounding-off of the workpiece are done simultaneously.