09ME64

1
A REPORT ON
“ABRASIVE AIR JET MACHINE”
Prepared By:
AKASH VYAS(09ME64)
DEPARTMENT OF MECHATRONICS AND MECHANICAL ENGINEER-
ING,
U.V.PATEL COLLEGE OF ENGINEERING,
GANPAT UNIVERSITY
GANPAT VIDYANAGAR,
KHERVA.
2013

2
A REPORT ON
ABRASIVE AIR JET MACHINE
A PROJECT REPORT SUBMITTED IN PARTIAL FULFILLMENT OF
THE REQUIREMENTS FOR THE DEGREE OF
BACHELOR OF TECHNOLOGY
(MECHANICAL ENGINEERING)
BY
AKASH VYAS (09 ME 64)
UNDER THE GUIDANCE OF
MR. UCHIT. J. PATEL
AT THE
U.V.PATEL COLLEGE OF ENGINEERING,
GANPAT UNIVERSITY,
GANPAT VIDYANAGAR, KHERVA
2013

3
CERTIFICATE
This project work is the bonafide work done by AKASH VYAS Roll No. 09 ME 64,
student of VIII semester of Mechanical Engineering Department of U. V. Patel College
of Engineering, under the guidance of Mr.Uchit j patel towards the partial fulfillment
of the requirements for the Degree of Bachelor of Technology (Mechanical) of Ganpat
University, Ganpat Vidyanagar.
Guide : ______________________________
Internal Examiner: ____________________
External Examiner: ____________________
Head of Department: ___________________

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ACKNOWLEDGEMENT
The project work has been the most practical and invigorating experience of our student
carriers thus far, which would be an asset for us in our professional pursuits
We would like to embrace this opportunity to express our profound gratitude to all those
who have assisted and guided us at various stages of the project.
Our most sincere thanks to our project guide Mr. Uchit J Patel for his invaluable co-
operation and technical insights throughout the course of this literary work. We would
like to believe that we were fortunate to have Mr. Uchit J patel with his rich teaching ex-
perience & practical exposure as our guide & that made our journey quite pleasant & re-
warding.
We are also greatly thankful to entire Mechanical Department Staff who have helped us
in completion of this project directly or indirectly. Names worth mentioning here are Mr.
Vikram B. Patel (H.O.D.) & Mr. Anil K Patel (Mechanical Engineering Department)
who offered useful advice & extended their helping hand at various stages of the project.
Without the support & co-operation of these gentlemen, the completion of our project
would have been a distant dream.
There is no doubt that in spite of our best efforts; some errors might have crept in. Addi-
tionally, this being a design & production project, there may be scope for further sugges-
tion and debate. We would appreciate if these facets are brought to our notice.
Akash Vyas

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ABSTRACT
Recent developments in metallurgical sciences have developed materials such as nitralloy
, nimonics and many varieties of heat-resistant steels.
The convential machining processes with all technological advances have been found in-
adequate to machine this materials. Machining of these difficult to machine materials
forced the unconventional machining processes to be developed.
Turning, drilling, boring , planning ,etc are the conventional machining processes. This
process is used for machining soft and ductile materials such as MS, CI, etc. in this
process to be developed. In this process cutting tool is used and material is removed by
action of cutting force.
From some time past engineering industries have withnessed a rapid growth in the devel-
opment of harder and difficult to machine materials such as hastalloy nitralloy , wasp al-
loy , nimonics , carbides , ss , heat-resisting steels , and many other high strength-
temperature-resistance(hstr) alloys.
These materials find wide applications in aerospace, nuclear engg, and other industries
owing to their high strength-to-weight ratio, hardness, and heat-resisting qualities.
For such materials the conventional edged tool machining is highly uneconomical and the
degree of accuracy and surface finish attainable are poor. it is also difficult to machining
of these materials into complex shape is difficult, time consuming and sometimes imposs-
ible. Considering this seriousness of these problems new processes have been invented
and are also in the course of invention. this new processes are called unconventional ma-
chining processes in sense of that do not employ a conventional tool for metal removed,
instead they directly utilize some form of energy for metal machining. The Schematic re-
presentation of various cutting operations is given in figure no. ------
Thus, classification of NTM processes is as shown in Table no. ------, is carried out de-
pending on the nature of energy used for material removal.

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Mechanical Processes Electrochemical
Processes
Electro-Thermal
Processes
Chemical Processes
Abrasive Jet Machining
(AJM)
Electrochemical Ma-
chining (ECM)
Electro-discharge ma-
chining (EDM)
Chemical Milling
(CHM)
Ultrasonic Machining
(USM)
Electro Chemical
Grinding (ECG)
Laser Jet Machining
(LJM)
Photochemical Mil-
ling (PCM) etc
Water Jet Machining
(WJM)
Electro Jet Drilling
(EJD)
Electron Beam Ma-
chining (EBM)
Abrasive Water Jet
Machining (AWJM)
[Fig : 1.1 Schematic representation of various cutting operations]

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INDEX
Sr.
No.
Subject Page No.
1 ABSTRACT 1
2 INTRODUCTION 4
3
SCHEMATIC LAYOUT AND PRINCIPLE OF
OPERATION
5
4 OPERATION OF ABRESIVE JET MACHINING
PROCESS
6
5 VARIABLE IN ABASIVE JET MACHINE 7
6 MEAN NUMBER OF ABRESIVE GRAIN PER
UNIT VOLUME OF CARRIER GAS
13
7 PROCESS PARAMETERS AND MACHINING
CHARACTERISTICS
14
8 The important machining characteristics in
AJM
16
9 COMPARISON TO OTHER MACHINING
PROCESSES
17
10 MACHINABLE MATERIALS 21
11 Application 22
12 ADVANTAGES OF ABRASIVE JET 24
13 LIMITATIONS OF ABRASIVE JET 27
14 Nozzle design 29
15 Control panel 30
16 Design of cabinet for mixing unit and design
of cabinet for machining unit
31
17 About Abrasive Jet Cutting Machines 32
18 CNC Machines 33
19 CNC Water jet Cutting Machine 34
20 Air jet Mill 36

8
21 CNC ultra-high pressure water jet 38
22 Affrodable Water Jet Cutting Machine 40
23 CNC abrasive waterjet cutting machine:
41
24 CNC hydraulic press brake - multi axis 43
25 CNC Hydraulic Shear Or Shearing Machin 44
26 cnc precision turret punch press
46
27
Water Jet Machining
47
28
Sand-blasting machine
48
29
Conclusion
49
30
Reference
50

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INTRODUCTION
Abrasive jet machining process is the mechanical metal removal process and is a process
in which material is removed from the work piece due to impingement of fine grain abra-
sive by a high velocity gas stream .In this case the stream of a fine grinding abrasive
mixed with air or some other carrier gases ,at high pressure, is directed by mines of suita-
bly design nozzle on to work surface to be machined. This process defers from the con-
ventional sand blasting, in that the abrasive used is finer and the process parameter and
cutting action is carefully controlled.
Abrasive jet machining differs from conventional sand blasting. As in Abrasive jet para-
meters and cutting action are carefully controlle. Abrasive jet cutting is applied to cut
hard and brittle materials such as Germanium, Mica, Glass, Ceramics, etc.
This process is free from vibration and chatter problems. As no current passes between
the tool and work piece, There is no restriction on material to be machined. Thus, it cuts
conductive as well as non-conductive materials.
The process, however, is not cunductive to machine soft materials [metals] due to the
abrasive particles getting imbedded in the work material.

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SCHEMATIC LAYOUT AND PRINCIPLE OF OPERATION
The pressure air [carrier gas] from the compressor passes through filter and control valves
in to the mixing chamber. The fine abrasive particles and carrier gas [air in this case] are
thoroughly mixed in these mixing gases passes through a nozzle on the work piece. The
AJM setup is as shown in figure number 1.2.
[Fig: 1.2 AJM setup ]
Impact of high velocity abrasive particles strikes upon the work piece surface and materi-
al is sheared, fractured and material is removed. The cutting action is cool, because the
carrier gas also serves as coolant.

11
OPERATION OF ABRESIVE JET MACHINING PROCESS;-
The filtered gas is supplied under a pressure of 2 kgf/sq, cross to 8 kgf/sq. cms to the mix-
ing chamber containing the abrasive powder and vibration at 50 Hz entrains the abrasive
particles and is then passed in to a connecting hose.
This abrasive and gas mixture emerges from a small nozzle mounted on a fixture at high
velocity. The abrasives power feed rate is controlled by the amplitude of vibration of mix-
ing chamber. A pressure regulator controls the gas flow and pressure. To control the size
and shape of cut either the work piece or nozzle is moved by cams pantographs or other
suitable mechanisms.
The metal removal rates depends upon the diameter of nozzle, composition of abrasive-
gas mixture, hardness of abrasive particles and that of work material, particle size, veloci-
ty of jet and distance of work piece from the jet[NTD]
VARIABLE IN ABASIVE JET MACHINE
Variables that influence the rate of metal removal and accuracy of machining in AJM
process:
1. Carrier Gas
2. Types of Abrasives
3. Size of Abrasive Grains
4. Velocity of Abrasive Jet
5. Stand Off
6. Work Material
7. Nozzle Designed
1. Carrier gas
The carrier gas should not excessively in to the atmosphere. The gas should have some
properties like
a. Non-toxic
b. Easily available
c. Cheap

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d. Drying and cleaning should not be difficult
Some of the most commonly used carrier gases are air, carbon dioxide, nitrogen. Of all air
is most commonly used carrier gas. As its properties satisfies the requirements of carrier
gas while using air ‘Air filters’ should be strictly employed.
2. Types of abrasives
This choice of the abrasive in abrasive jet machining depends upon the type of machining
operation i.e. roughing, finishing, etc., work material and cost. The abrasive should have
sharp and irregular shape and be fine enough to remain suspended in the carrier gas and
should have excellent flow characterics.
Aluminium oxide is an amphoteric oxide of aluminium with the chemical formula Al2O3.
Three dimensional structure of Al2O3 given in figure number 1.3.
[Fig.no.1.3 Three dimensional structure of Al2O3 ]

13
It is also commonly referred to as alumina, corundum, sapphire, ruby, alundum (in fused
form) or aloxite[3]
in the mining, ceramic and materials science communities. It is
produced by the Bayer process from bauxite. Its most significant use is in the production
of aluminium metal, although it is also used as an abrasive due to its hardness and as a
refractory material due to its high melting point.
Properties of Al2O3
Aluminium oxide is an electrical insulator but has a relatively high thermal conductivity
(30 Wm−1
K−1[5]
) for a ceramic material. In its most commonly occurring crystalline form,
called corundum or α-aluminium oxide, its hardness makes it suitable for use as an
abrasive and as a component in cutting tools.
Aluminium oxide is responsible for resistance of metallic aluminium to weathering.
Metallic aluminium is very reactive with atmospheric oxygen, and a thin passivation layer
of alumina (4 nm thickness) forms in about 100 picoseconds on any exposed aluminium
surface. This layer protects the metal from further oxidation. The thickness and properties
of this oxide layer can be enhanced using a process called anodizing.
A number of alloys, such as aluminium bronzes, exploit this property by including a
proportion of aluminium in the alloy to enhance corrosion resistance. The alumina
generated by anodizing is typically amorphous, but discharge assisted oxidation processes
such as plasma electrolytic oxidation result in a significant proportion of crystalline
alumina in the coating, enhancing its hardness.

14
3. Size of abrasive grains
Rate of material removal in abrasive jet machining depends upon the size of grain. larger
sizes bare used for rapid removal rate while smaller sizes are used for good surface finish
and precision work. More ever,finer grains tend to stick together vand chock the nozzle.
The most favorable grain size in abrasive jet machinining ranges from 10 microns to 50
microns and they are generally available in 10, 27,40,and 50 microns sizes.
Particle size is important and best cutting results have been obtained if the bulk particles
vary between 15 microns and 40 microns.
4. Velocity of the abrasive jet
The kinetic energy of the jet is abilited in removing the metal from the work piece .the
velocity of the abrasive stream should be high of the order of about 300 m/sec. the expe-
riment conducted by Finnie and shadow have shown that a minimum jet velocity is neces-
sary for cutting. in their experiments with sodium bicarbonate, abrasive of grain size .25
microns on glass ,the minimum jet velocity was found to be 150 m/sec.
The jet velocity in abrasive let machining in a function of the nozzle pressure , nozzle de-
sign, abrasive grain size and the mean number of abrasive per unit volume of the car-
rier gas.
Metal removal by erosion uses the kinetic energy of abrasive jet. The velocity depends
on the factors like
a. Nozzle pressure
b. Nozzle design
c. Size of abrasive grain
d. Mean number of abrasives per unit volume of carrier gas
5. Standoff distance

15
It is the effective distance between the nozzle tip and the work piece as in figure number
1.4. It has a considerable affect on the rate of material removal. If a small standoff dis-
tance is maintained there is every chance of the penetration of abrasive particles in to the
work piece. If lager standoff distance is maintained flaring may take place. It is found
from various experiments that the effective standoff distance is 0.8mm.
[ Fig. No. 1.4 Effective distance between the nozzle tip and the work piece ]
6. Work material
Abrasive jet machining is generally used for machining brittle materials like glass, ceram-
ics etc. The effective metal removal rate highly depends on the hardness of work piece
material. Ductile materials are partially unmachinable by abrasive jet machining. Brittle
material such as
Glass,
Ceramics,
Refractories etc.
Most of the ductile materials are practically unmachinable by AJM due to particles get-
ting imbedded in the work material.
7. Nozzle design

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Nozzle has to withstand various conditions like erosive action of abrasive materials, pres-
sure and kinetic energy of jet.
[Fig.No.1.5. Nozzle design]
The most commonly used materials for nozzle are sapphire, tungsten carbide. Pressure
losses at the end of nozzle should be very low. One nozzle design is given in figure num-
ber 1.5.
Depending on the requirements the nozzle may be designed either in rectangular or circu-
lar cross sections.
MEAN NUMBER OF ABRESIVE GRAIN PER UNIT VOLUME OF
CARRIER GAS
An idea about the mean number of abrasive grains per unit volume of the carrier gas can
be obtained from the mixing ratio [M]. The mixing ratio is the ratio of volume flow rate
of the abrasive per unit time to the volume flow rate of the carrier gas per unit time.
A large value of [M] should result in to higher rate of metal removal but large abrasive
flow rate has been found to influence abrasive the jet velocity and some times clog the
nozzle. Thus, for the given conditions there is an optimum [M] that leads to maximum
metal removal rate.
The maximum cutting rate is obtainable for the fixed nozzle dimensions and stand off
[NOZZLE TIP DISTANCE] usually lies between 2 to 20 mm.

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PROCESS PARAMETERS AND MACHINING CHARACTERISTICS
There are different process parameters such as
1. Abrasive materials with its characteristics is listed in the Table 1.2
2. Carrier gas is listed in the Table 1.3
3. Abrasive jet is listed in the Table 1.4
4. Nozzle are listed in the Table 1.5
Abrasive
Material Al2O3 / SiC / glass beads
Shape irregular / spherical
Size 10 ~ 50 µm
Mass flow rate 2 ~ 20 gm/min
[Table 1.2 : Abrasive materials with its characteristics ]
Carrier gas
Composition Air, CO2, N2
Density Air ~ 1.3 kg/m3
Velocity 500 ~ 700 m/s
Pressure 2 ~ 10 bar
Flow rate 5 ~ 30 l pm
[Table 1.3 : Carrier gas ]

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Nozzle
Material WC / sapphire
Diameter (Internal) 0.2 ~ 0.8 mm
Life 10 ~ 300 hours
[Table 1.5: Nozzle]
The important machining characteristics in AJM are
1. The material removal rate (MRR) mm3/min or gm/min
2. The machining accuracy
3. The life of the nozzle
4. Depicts the effect of some process parameters on MRR
Abrasive Jet
Velocity 100 ~ 300 m/s
Mixing ratio 1
Stand-off distance 0.5 ~ 5 mm
Impingement Angle 600 ~ 900

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COMPARISON TO OTHER MACHINING PROCESSES
1. Comparison with EDM
Key Wire EDM strengths
o Extremely precise parts are possible [ą0.0001" (ą0.025mm)]
o Very thick parts [over 12" (30 cm)] can be made
o Intentional taper can be put into a part for die clearance and other uses
Key Precision Abrasive jet strengths
o Five to ten times faster in parts less than 1" (2.5 cm) thick [but, at ą0.003"
(ą0.1 mm), less precise as well
o No Heat Affected Zone (HAZ), so no need for secondary operations to
remove the HAZ or additional heat-treating to compensate for it
o Works well in non-conductive materials (such as glass, stone, plastic) as
well as conductive materials
o Can pierce material directly without the need for a pre-drilled starter hole
o Can produce large parts at reasonable costs
Simple and rapid programming and set-up with minimal fixturing

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2. Comparing abrasive jet to laser
Key laser strengths
o Very fast production in thin, non-reflective materials such as sheet steel.
o Accuracy to ą0.001" (ą0.025 mm) or better in thin material.
Key precision abrasive jet strengths
o Can produce parts up to 2" (5.1 cm) thick in virtually any material while
holding tolerances on the order of ą0.003" to ą0.005" (ą0.08 to ą0.1 mm).
o Can machine reflective, conductive and thicker materials such as stainless
steel and aluminum, copper and brass.
o Cuts without melting, providing a smooth uniform surface with very little
burr or dross.
o No heat-affected zone (HAZ), which may eliminate the need for a second-
ary operation to remove HAZ and makes conventional secondary opera-
tions, such as reaming or tapping, easier to perform.
o No noxious gas or vapors produced during cutting.
o Simple and rapid programming and set-up for short-run parts.
3. Comparison of precision abrasive jet to milling
Key mill or machining center strengths
o A well-understood familiar technology.
o Able to make three-dimensional parts.
o Rapid production if set up and programmed for long-run parts.

21
o Very rapid programming and set-up does not require a highly trained oper-
ator.
o Very low cutting loads means that fixturing is easier and also means that
intricate and delicate parts can be machined.
o One cutting tool performs all machining functions in all materials, so there
is no need to purchase and calibrate multiple cutting tools.br>
o Large cutting envelope compared to a machining center of comparable
price.
o Minimal burr compared to conventional machining.
Environmentally friendly; no oil-soaked chips and minimal scrap.
o The key reasons traditional job shops buy a precision abrasive jet is to get
new projects, become more competitive, and make more money.
5. Comparison of precision abrasive jet to milling
Key mill or machining center strengths
o A well-understood familiar technology.
o Able to make three-dimensional parts.
o Rapid production if set up and programmed for long-run parts.
o Very rapid programming and set-up does not require a highly trained oper-
ator.

22
o Very low cutting loads means that fixturing is easier and also means that
intricate and delicate parts can be machined.
o One cutting tool performs all machining functions in all materials, so there
is no need to purchase and calibrate multiple cutting tools.br>
o Large cutting envelope compared to a machining center of comparable
price.
MACHINABLE MATERIALS
Virtually any material can be cut by using AJM method i.e. harder materials like titanium
to steel
Aluminum, Steel, Titanium Laminates
Flammable materials
Cut thin stuff, or thick stuff
Brittle materials like glass, ceramic, quartz, stone.
Laminates
Flammable materials
Cut thin stuff, or thick stuff
Application
The applications and materials, which are generally machined using WJ
and
AWJ, are given below:
-Removal of flash and parting lines from the injection moulded parts.
-for cleaning of the spark plug and casting.
-Production of high quality surface.
-Paint removal
-Cleaning

23
-Cutting soft materials
-Cutting frozen meat
-Textile, Leather industry
-Mass Immunization
-Surgery
-Peening
-Cutting
-Pocket Milling
-Drilling
-Turning
-Nuclear Plant Dismantling
Materials
•Steels
•Non-ferrous alloys
•Ti alloys, Ni- alloys
•Polymers
•Honeycombs
•Metal Matrix Composite
•Ceramic Matrix Composite
•Concrete

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•Stone – Granite
•Wood
•Reinforced plastics
•Metal Polymer Laminated
ADVANTAGES OF ABRASIVE JET
(a) Extremely fast setup and programming
No tool changes required, so there is no need to program tool changes or physically quali-
fy multiple tools. For some systems, programming simply involves drawing the part. If
you customer gives you that drawing on disk, half the battle is won.
This means that (for some machines) you can make good money off single part and low
volume production!
(b)Very little fixturing for most parts
Flat material can be positioned by laying it on the table and putting a couple of 10 lb
weights on it. Tiny parts might require tabs, or other fixturing. At any rate, fixturing is
typically not any big deal.
Machine virtually any 2D shape (and some 3D stuff)
Including tight inside radii, Make a carburetor flange with holes drilled and everything.
(c)Very low side forces during the machining
This means you can machine a part with walls as thin as .025" (0.5 mm) without them
blowing out. This is one of the factors that make fixturing is so easy. Also, low side
forces allow for close nesting of parts, and maximum material usage.
(d)Almost No heat generated on your part

25
You can machine without hardening the material, generating poisonous fumes, recasting, or
warping. You can machine parts that have already been heat treated with only a tiny, tiny de-
crease in speed. On piercing 2" (50mm) thick steel, temperatures may get as high as 120 degrees
F (50 C), but otherwise machining is done at room temperature.
Aerospace companies use abrasive jets a lot because of this.
(e)No start hole required
Wire EDM, eat your heart out. Start holes are only required for impossible to
pierce materials. (Some poorly bonded laminates are about the only mate-
rials I can think of off hand)
(f)Machine thick stuff
This is one huge advantage Abrasive jets have over lasers.
While most money will probably be made in thickness' under 1" (25mm) for steel, It is
common to also machine up to 4" (100mm). I don't know the actual limit to thickness, but
cutting speed is a function of thickness, and a part twice as thick will take more than
twice as long. I have heard of people making low tolerance parts and roughing out metal
up to 5-10" thick (125mm-250mm), but those people are very patient, and probably have
no other way to do it. Typically, most money is made on parts 2" (50mm) thick or thin-
ner.
(g)Environmentally friendly
Green Peace does not like some of those other tools in your shop. Not much of an issue
now, but in the future I would expect the pressure will be on. Short of hand tools, abrasive
jets provide the most environmentally friendly machining around. (Some of the pumps
even use vegetable oil for assembly lube because water jets are used in the food industry).
As long as no hazardous material is machined, the spent abrasive and waste material be-

26
come suitable for landfill. The red color of garnet abrasive also looks nice in your garden.
If lots of lead or other hazardous materials are machined, you will still need to dispose of
your waste appropriately, and recycle your water. Very little metal is actually removed in
the cutting process. This keeps the environmental impact relatively low, even if you do
machine the occasional hazardous material.
(h)Your clippings are valuable
When machining or roughing out expensive materials such as titanium, your scrap still
has value. This is because you get chunks, not chips. You can also get more parts from
the same material because of the abrasive jets low kerf width.
(i)There is only 1 tool
There is no need to qualify multiple tools, or deal with programming tool changes. Pro-
gramming, Setup and Clean up time is reduced significantly, meaning you make more
money because you can turn more parts faster.
(j) It can cut holes of intricate shapes in materials of any hardness and brittleness.
(k) There is no mechanical contact between tool and work.
(l) it can machine thin sections of hard and brittle materials without damage as no heat
generated to the passing of gas or air.
(m)Accuracy up to 0.o5mm can be obtained.

27
LIMITATIONS OF ABRASIVE JET
 Despite their simple design, abrasive jet nozzles can be troublesome at times.
There are many designs, but they share the same problems:
Short life of an expensive wear part: The mixing tube. Like I said, the abrasive
jet can cut through just about anything - including itself. This will be a large part
of your operating cost. (More on operating cost later)
 Occasional plugging of mixing tube: Usually caused by dirt or large particles in
abrasive. (This used to be a big problem with abrasive jet nozzles, but not so
much any more.)
 Wear, misalignment, and damage to the jewel.
 Nozzle wear is high.
 Metal removal rate is low and its application is therefore limited
Comparative study of unconventional machining process.:
In order to select the right process for manufacture of any components, following infor-
mation is required.:
-Nature of machining problem.
-Physical parameters involved.
-Operating characteristics of machine
-Economics of possible manufacturing processes.
A comparative study of various process is therefore, of prime importance in the
selection of a judged from the stand point of reliability of the manufacturing engg. Has to
remember that conventional machining process should always be appreciated better when
a few conventional and non conventional proccess are considered.

28
EDM, ECMAND ECG Processes can not be applied to those materials which are
electrically not conductive. ceramics can be machined by sums, aim ,ebb and lbm.
Microdriling and drilling operations:
Machining by unconvential processes is also influenced by the shape and size of the com-
ponents. Considering micro-drilling and drilling operations. It is seen that holes lesser
than 0.03 mm diameter can be drilled only by LBM process.
Voltage current and power requirements
Parameter Voltage(volt) Power(KW) Current(amp.)
USM 220 2.5 12AC
AJM 200 0.25 1.0
EDM 45 2.5 50 PULSED DC
ECM 10.25 100 10000 DC
This table gives comparative information in connection with different unconventional
processes. It will be seen that normal applied voltage of 220 to suitable for USM and
AJM processes.

29
Nozzle design
The function of the nozzle is to convert the static head of abrasive jet in to kinetic energy,
required for machining. the present project consider general purpose nozzle with 1 mm
office diameter and 5 degree semi-cone angle.
Control panel
The entire abrasive jet machining system is designed for control and operation at
230 volts,1-phase ,A-C. supply.
As far as the operation is concerned 230 volts is required for operating the mixing
chamber. the control of carrier gas and abrasive jet is required for proper operation sys-
tem.
Design of cabinet for mixing unit and design of cabinet for machining unit
Separate cabinets rae designed for mixing and machining, to prevent exposure of
delicate pneumatic system components such as filter regulator, solenoid valves to abra-
sive particles.
Fabrication
1-fabrication of mixing chamber:
-mixing chamber fabrication is realized from fabrication of two components storage com-
partment and mixing cone.
2-Fabrication of nozzle
-since nozzle material (H.S.S) is very difficult to machine for a given cone angle. the ma-
jor mt. are removed by drilling operation of several driil steps.

30
3-Fabrication of cabinate for mixing units
-Angle frame box structure with thin plastic sheets convering the slides, Is fabricated to
house the mixing unit with pneumatic system.
About Abrasive Jet Cutting Machines:
Abrasive jet cutting machines are used to cut sheet materials or to remove ma-
terials from a surface by generating a focused stream of fluid mixed with abrasive par-
ticles. They may use pressurized water or compressed air as the driving fluid to propel
the abrasive particles. Abrasive jet cutting machines are available as complete systems
with all of the components required for the blasting or jet machining applications such as
pressure generation / intensification, cabinets, nozzles or wheels, and dust collectors; or
they may be purchased in component form to either build a custom system from the
ground up, or to replace worn out parts.
Abrasive jet cutting machines includes four main types of devices (not including
proprietary or custom devices, which can be designed by suppliers as necessary), abrasive
water jet cutters, air abrasive jet cutters, and precision blasters or micro-jets. Abrasive
water jet cutting machines use abrasive grains entrained in a stream of water to cut
through metal, composite or other materials in sheet or web forms. Garnet grain is widely
applied as the abrasive media in abrasive water jet cutting. Air abrasive jet cutters are
employed in similar circumstances, although they use air as the propelling fluid. The ab-
rasive grains most commonly used air systems are aluminum oxide or silicon carbide.
Precision abrasive blasters or micro-jets produce extremely fine and precise streams.
They are used for drilling, detailing and precision cutting of printed circuit boards and
other high quality components.
In addition to cutting abrasive jet cutting machines can perform a number of sec-
ondary procedures. These include sectioning (cutting patterns out of sheet or plate mate-
rials), deburring and deflashing (removing sharp edges or discontinuities from a part) de-
molition (the destruction of structures or walls constructed of building materials. Hydro-
demolition usually refers to the destruction of concrete structures or walls.), descaling
(the removal of heat-treat scale, surface discoloration, oxides, rust, weld scale or corro-

31
sion that ruins appearance and interferes with welding, painting, plating, coating, drawing
and other processes.), stripping (the removal of an existing protective coating or paint
layer to facilitate welding, recoating or adhesive joining), and web slitting (these abrasive
jet cutting machines typically have a coil feeder, winder or rewinder).
CNC Machines:
CNC machines offers high precision machined components via CNC milling machines
and turning machines known as CNC Machining Center or CNC Machines Center that
can perform multiple machining operations with various type of cutting tools by utilizing
the latest techniques and technology to give the extremely accurate and precise machined
components.
CNC Water jet Cutting Machine
What is Water jet Cutting Machine? A Water jet Cutting Machine is a machine tool
uses a specific and a consistent high pressure pressurized water called water jet which
supplied by high pressure pump to cut or pierce variety of metal or non-metal materials.
CNC Water jet Cutting Machine is consistently deliver an extremely high level of
cutting precision, accuracy and performance that fully utilize the water jet cutting tech-
nology which uses CNC G codes and CNC M codes to control the overall machine cut-
ting process.
There are two type of water jets used by Water jet Cutting Machines to cut mate-
rials. There are Pure Waterjet and Abrasive Waterjet. A Water jet Cutting Machine
might used pure water jet or abrasive water jet or both method to cut almost any mate-
rials. Pure water jet uses to cut a variety of soft materials such as paper, rubber, foam and
baby diapers. The abrasive water jet uses to cut almost any hard materials such as tita-
nium, stainless steel, stone and glass.

32
How a Water jet Cutting Machine Works?
How Water jet Cutter works? Basically, the Waterjet Cutter or Waterjet Cutting
Machine uses the technology of high pressurized water supplied by high pressure pump
and delivers it consistently and continuously up to 90,000 psi or 6200 Bar (620 MPa) and
forced it through a pre-mounted orifice or small hole as small as 0.005 inches (0.127
mm), it will create a jet stream called pure water jet
If a small amount of abrasive material such as granet is mixed into the jet stream, it
will create a jet stream called abrasive jet or abrasive water jet. The jet stream flow exits
the nozzle will make contact with the surface of work piece. The work piece will develop
small cracks due to jet stream impact and propagate until the material is cut through.

33
CNC Water jet Cutting Machine – JET Max HS 4020

34
Air Jet Mill (LHL/Y)
Air Jet Mill (LHL/Y)
Product Description
Working principles
Depending on pressurized gas supplied by a compressor enters into the crushing chamber
via jet nozzles at high speed, the size reduction is accomplished owing to the drastic colli-
sions between particles through the transmission of energy, and then the ground particles
travel to the classifying district with upward air, where the oversize is rejected and the
fine is collected, and finally the filtered air is exhausted.
FEATURES
1. Energy consumption can be saved by 30%, compared with the traditional jet mill.
2. Being equipped with 1-4 Classifiers, it can directly give the several products in narrow
distribution.

35
3. The structure is compact, saving plant area.
4. No storage, no dead angle in the grinding chamber, it is easy to be dismantled and
cleaned, disinfected, and convenient for variety rotation.
5. It operates at lower temperature and there is no media being ground, especially suitable
for grinding of low melting point and thermo-sensibility materials, sugary materials and
volatile materials.
6. The flammable and explosive materials can be used with Inert gases, which can be pe-
riodic duty.
7. The product size can be given within 3~180¦Ìm according to your requirement, the spe-
cification is complete, and can be selected according to the output within 5~3000Kg/h.
8. The production control is automated under the negative pressure, simple handle, stable
operation, and no environment pollution.
9. The system is automized and handle easily.
APPLICATIONS
1. Used in chemical industries, mining, abrasive material, refractory material, non-metal
mines, metallurgy, building materials, pharmacy, food, pesticide, feedstuff, new mate-
rials, environmental protection and other fields.
2. Used for ultra fine grinding, de-aggregating and shaping grain for all kinds of dry ma-
terials.
CNC ultra-high pressure water jet:
Description features
Siemens CNC ultra-high pressure water jet cutting machine is to use intensifier
pump to pressurize normal tap water to 100-300Mpa in a split second. Then convert water
pressure to dynamic energy through diamond orifice mount assembly. This creates a very

36
high velocity beam of water jet to generate high speed friction to make cutting. Water jet
cutting is suitable for cutting almost all the materials, such as glass, marble, metal, rubber
and wood , and many advantages of it will be greatly found during different materials cut-
ting.
Components of the whole set of machine are as follows:
1. Cutting table: flying arms style, Z-axis journey is 150mm, Three-axis control, Auto
zero positioning, drives and motors are FUJI brand from Japan, All screw and linear
guide are ABBA brand from Taiwan.
2, Intensifier pump: Intensifier pump is JETLINETMJL-1 pump from Germany KMT
company's branch in Shanghai
3. CNC controller: EVOC brand Industrial Personal Computer and 17BENQ LCD, spe-
cialized water jet cutting software, Omron brand PLC instead of relay,
Windows XP based.
4. Accessories: spare parts and deionization system.
5. New products: 4-axis cutting head, 5-axis cutting head and auto abrasive feeder.
Common used models and their technical data are as follows:
APW38037Z-JETLINETMJL-1 BB Flying arms style series technology data
Table model1210BB2010BB2015BB2515BB4015BB
Cutting area1.2m 1.0m2.0m 1.0m 2.0m 1.5m2.5m 1.5m4.0m 1.5m
Max moving speed6000mm/min6000mm/min6000mm/min6000mm/min6000mm/min
Way of driveAC servoAC servoAC servoAC servoAC servo
Control accuracy 0.01 0.01 0.01 0.01 0.01
Cutting accuracy 0.1~ 0.2 0.1~ 0.2 0.1~ 0.2 0.1~ 0.2 0.1~ 0.2
Pump modelJETLINETMJL-1 JETLINETMJL-1 JETLINETMJL-1 JETLINETMJL-1
JETLINETMJL-1
Max working pressure380Mpa380Mpa380Mpa380Mpa380Mpa
Motor rated current380V/50HZ 43 A380V/50HZ 43 A380V/50HZ 43 A380V/50HZ 43
A380V/50HZ 43 A
Control system Siemens Siemens Siemens Siemens Siemens
Max. water discharge2.3L/min2.3L/min2.3L/min2.3L/min3.79L/min
Compressed air pressure5.9 bar5.9 bar5.9 bar5.9 bar5.9 bar

37
6. Applications
This machine can be used in many materials cutting and has many advantages than other
cutting method, no heat, narrow kerf, good edge finish high accuracy.
The application is below:
metal works cutting
marble works cutting
glass works cutting
and granite, stone, metal ,steel, rubber, aluminum, plastic and other materials cutting.
7. Cutting speed
The cutting speed depends on the thickness of material, the thicker the slower. The fol-
lowing is the reference cutting speed of different material with different thickness.
Reference Cutting Speed
Affordable Water Jet Cutting Machine:
We have pleasure in introducing to you new maxiem cnc water jet machining
centers manufactured in use specially made for engineering work and architectural works
including metals, acrylic, glass and marbles etc. by unique process of abrasive water jet
and precision control through cnc, maxiem jet machining centers produces precision parts
on materials upto 200 mm thick in metal, acrylic, glass and stone. The machine is capable
of handling all type of material such as tool steel, aluminum, titanium, glass, wood, stone,
ceramic, fiber, polyurethane, plastic material, rubber etc. Since there is no heat generated
during the process, there is no distortion of the component and under ideal conditions ma-
chine can cut sharp external and internal corners. the machining process does not involve
any tool change and minimal fixturing of the component is involved. Water jet cutting
machine is having following benefits over the other machining process: f no heat affected

38
zones f no thermal distortion -no fumes produced while machining -cuts reflective, non-
reflective materials -cuts conductive, non-conductive material -can cut 200 mm thick ma-
terial in general, users of water jet machines are: -job shops / metal fabricators / laser
shops / wire cut edm shops -architectural fabricators works like marble inlay, glass inlay,
acrylic, designer jali etc -aerospace industries / armour panel manufacturer -tooling shops
-prototype and r & d shops -maintenance and repair shops -original equipment manufac-
tures maxiem (omax) is the only manufacturer in the world who manufactures their own
jet machining centers including the high pressure pump and cnc controller.
Cnc abrasive waterjet cutting machine:
We have pleasure in introducing to you new MAXIEM CNC Water Jet Ma-
chining Centers manufactured in USA specially made for Engineering Work and Arc-
hitectural Works including Metals, Glass and Marbles etc. By unique process of Abra-
sive Water Jet and precision control through CNC, MAXIEM Jet Machining Centers
produces precision parts on materials up to 200 mm thick in Glass, Stone and Metals.
The machine is capable of handling all type of material such as Tool Steel, Aluminum,

39
Titanium, Glass, Stone, Ceramic, Fiber, polyurethane, plastic material, rubber etc.
Since there is no heat generated during the process, there is no distortion of the com-
ponent and under ideal conditions machine can cut sharp external and internal corners.
The machining process does not involve any tool change and minimal fixturing of the
component is involved. Water jet Cutting machine is having following benefits over
the other machining process: * No heat Affected Zones * No Thermal Distortion * No
fumes produced while machining * Cuts reflective, non-reflective materials * Cuts
conductive, non-conductive Material * Can cut 200 mm thick material In general, us-
ers of Water Jet machines are: * Job Shops / Metal Fabricators / Laser Shops / Wire
Cut EDM Shops * Architectural Fabricators Works like Marble Inlay, Glass Inlay, De-
signer Jali etc * Aerospace Industries / Armor Panel Manufacturer * Tooling Shops *
Prototype and R & D Shops * Maintenance and Repair Shops * Original Equipment
Manufactures
cnc hydraulic press brake - multi axis
We are dealing with cnc press brake manufactured in turkey by one of the
world class manufacturer following are the standard features in our machine. * side safety

40
guards * givi- misure linear scales * unimec motorised backgauge x axis 500mm and
backgauge fingers -2pcs * cybelec dnc60 cnc digital (including offline software) or delem
da-52 cnc unit (without offline software) or esagv2005 cnc unit (including offline soft-
ware) * quick promecam type top tool clamping system * rolleri top tool p97-85-r08 - in
835mm lenghts hardened * sliding front supports in full lenght -2pcs optional extra axis
and special controllers are also available.
Cnc Hydraulic Shear Or Shearing Machine
We are dealing with nc and cnc guillotine shear. We have offices in gujarat
and maharastra. Product with hydraulic variable rake angle controlled by nc/cnc is also
available. Top quality and special material shearing blades are standard on our machine.
Sizes are available from 3 meter and upto 12 meter also available for cutting stainless
steel and mild steel for various thicknesses
1

41
Payment Terms: L/C (Letter of Credit), T/T (Bank Transfer)
FOB Price: 1 EUR
Port of Dispatch: Turkey
Production Capacity: Larger
Delivery Time: 1 month
Packaging Details: see worthy container
cnc precision turret punch press
We are distributors of CNC Turret Punch Press in India for one of
the world class manufacturer located in Turkey. Following are the standard
features of our machine: 4 axis CNC system FANUC CNC unit and servo
motors H + L ( Germany) hydraulics 30 ton punch force, 32 stations total
Thick Turret system with tool turret with 4 stations size D , 10A, 16B, 2C
stations. 2 indexing stations of size D Repositioning of clamps Quick drop-
ping of ram and operation at short stroke for increased productivity Refe-
rencing of sheet and clamps Operator's manual Further options are available.
For more details please contact us on rakeshpatel@mdcorpindia.com
Laser beams and water jets when used for cutting can be broadly suitable for
similar tasks:

42
WATER JET MACHINING
Water Jet Machining (WJM), otherwise known as Hydrodynamic Machining may be used
for tasks similar to those for a laser. Excepting welding for obvious reasons.
Water jet machining is used extensively for cutting plastics, fabric, rubber, paper and
leather due in part to the absence of heat. It produces a very narrow kerf, and if set cor-
rectly produces a very smooth edge with no rag or burrs. Water jet machining is a very
clean operation with no dust or odours and very little noise, in fact the health and safety
and environmental implications are almost negligible.
The nozzle can be mounted on a multi axis robot arm to cut complex three-dimensional
shapes; in fact this setup has been successfully employed cutting vehicle dashboards out
of laminated foam.
To cut harder and more resistant materials such as metal, abrasive particles such as Gar-
net or Alumina are added to the water prior to entering the cutting zone. This is known as
Abrasive Water Jet Machining (AWJ).
The pressures involved can be as high as 1400 MPa although 400 MPa is more usual for
efficient operation. The abrasive slurry is forced through an orifice in the nozzle between
0.05mm and 1mm in diameter at a rate of 0.5 liters to 25 liters per minute. This results in
a jet velocity in region 520 – 914 meters per sec. This acts like a saw blade, rapidly erod-
ing many materials. In fact due to the continually changing abrasive particles fresh cutting
edges are always being presented to the work piece, therefore they will not become dull
or blunt however resilient the material being cut.
The nozzle orifices are generally made of very hard materials, man-made ruby and sap-
phire as well as carbide based composites are currently in use.
Similarly to lasers the maximum thickness of cut, for most practical purposes is in the re-
gion of 25 mm.

43
Sand-blasting machine
Recycling sand-blasting machine, suitable for every surface. This system uses its handle
with a fore brush for the recovery of abrasive and the separation of powders.
 Completely automatic system
 Trolley for easy movements
 High blasting speed, in absence of powder
 Low air consume (it can work with a 7.5 Hp compressor)
 1200 Watt suction engine
 Blasting power adjustment, from 2.5 to 10 Bar
 VIDIA tungsten carbide abrasive nozzle
 Wide fabric separating filter

44
Conclusion
The better performance, and the applications presented above statements confirm that ABRA-
SIVE JET MACHINING (AJM) will continue to expand. Industry is convinced that the large
aerospace segment will take off in near the future, together with other segments that are currently
showing interest in AJM method. From operator experiences the abrasive jets are capable of any-
where from 0.5mm-0.025mm precision. High precision manufacturing needs can be met by using
AJM method. Newer machines are capable of 3D machining thus making it an important in spe-
cialty manufacturing. The new software’s used will minimize time and investments, thereby mak-
ing it possible for more manufacturers of precision parts to install AJM centers.

45
Reference
1-Materials and Processes in Manufacturing by E. Paul DeGarmo
Web.- www.amazon.com
2-Nontraditional Manufacturing Processes (Manufacturing Engineering and Materials
Processing) by Gary F. Benedict
3-Industrial Materials Science and Engineering (Manufacturing Engineering and Mate-
rials Processing) by Lawrence Murr

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