DESIGN and FABRICATION of ABRASIVE

GLASS CUTTING MACHINE USING

COMPRESSED AIR
Animesh Sawant1, Beerendra Parihar2, Gopikrishna Nemakal3, Sujit Kumar Singh4, Mrs. Shweta V. Matey5
1,2,3,4
Department of Mechanical Engineering, Mumbai University
Lokmanya Tilak College of Engineering, Kopar-Kharine, Navi Mumbai-400708, (INDIA)
1animesh.sawant09@gmail.com

2arnalaka@gmail.com

3gopikrishna799@gmail.com

4sujitkumar.rsingh@gmail.com

5
Assistant Professor, Department of Mechanical Engineering, Mumbai University
5
Department of Mechanical Engineering, Mumbai University
Lokmanya Tilak College of Engineering, Kopar-Kharine, Navi Mumbai-400708, (INDIA)
5
svmltjss@gmail.com

Abstract The machining operation is basically termed a
material removal process, where material is removed in the form
of chips. Abrasive jet machining is an effective machining
process for processing a variety of brittle and hard material. This
paper presents an extensive review of the current state of
research and development in the abrasive jet machining process.
And has various distinct advantages over the other non-
traditional cutting technologies, such as, high machining
versatility, minimum stresses on the work piece, high flexibility
no thermal distortion, and small cutting forces. This review
paper will help researchers, manufacturers and policy makers
widely.
Keywords Non-Traditional, Abrasive, Material removal
rate(MRR), Nozzle Tip Distance.
I. INTRODUCTION
Abrasive jet machining (AJM) is a processing non-
traditional machine which operators on no physical contact
between tool and work piece so there is no thermal stresses
and shocks developed. AJM is applied for many applications
like cutting, cleaning, polishing, deburring, etching, drilling
and finishing operation. In Abrasive jet machining abrasive
particles are made to impinge on work material at high
velocity.
Jet of abrasive particles is carried by carrier gas or air. The
high velocity stream of abrasives is generated by converting
pressure energy of carrier gas or air to its Kinetic energy and
hence high velocity jet. Nozzles directs abrasive jet in a
controlled manner onto work material. The high velocity
abrasive particles remove the material by micro-cutting action
as well as brittle fracture of the work material.
The process parameters are used like variables which effect
metal removal. They are carrier gas, abrasive, and velocity of
abrasive, work material, and nozzle tip distance (NTD).
Abrasive jet cutting is used in the cutting of materials like:
Titanium, Brass, Aluminium, Stone, Any Steel, Glass,
Composites, Plastics, Ceramics, Tungsten carbide etc.
II. LITERATURE REVIEW
In AJM process a focused stream of abrasive particles
carried by high pressure gas or air at a velocity of about 150 -
180 m/sec are made to impinge on the work surface through a
nozzle and the work material is removed by erosion by the
high velocity abrasive particles. The abrasive particles should
have regular shape and consist of sharp-edged. The abrasive
particles are directed into the work surface at high velocity
nozzle. The abrasive particles used were SiC (grain size 100
microns and 200 microns). The nozzle material was stainless
steel and the nozzles used were of diameters 1 mm and 0.5
mm.
In this process the abrasive particles at high velocity erodes
the metal or the work-piece. The small diameter of nozzle
helps the abrasive to be focused and thus to cut very small
section. Air or gas supplied with the abrasive jet acts as a
carrier and also the heat removal agent. Because of this there
is no thermal strain occurred on the work, also there is no
contact between tool and work.
A. Parameters Involved in AJM (Metal Removal Rate)
Abrasives
Abrasive particle size
Abrasive jet velocity
Carrier gas
Mean number of abrasive particle per unit volume of gas
Work material
Type of cut
Nozzle characteristics
B. Grain Size A. Design Procedure
TABLE I As per the data collected from various references we came
TYPE OF GRAIN SIZE to a final drawing lay out of our project which is attached
Grain Size Surface along with this project work. First we concentrated on the
Abrasive main powder feeding mechanism, i.e. hoppers (powder mixing
Sr. No (in Finish(in
Type chambers). From calculations we considered 16 gauge M.S.
Microns) mm)
1 Very Coarse 6 14 Above 0.9 Sheet so as to withstand pneumatic pressure as high as 10
kg/cm2, considering it as closed vessel. Then step by step we
2 Coarse 16-30 0.8
designed, then frame for that we collected it from college
3 Medium 36-60 0.7 campus which is suitable for our set up.
4 Fine 70-120 0.42-0.6 TABLE II
5 Very Fine 150-240 0.22-0.4 MATERIAL OF MAJOR COMPONENT OF SETUP

6 Super Fine 280-580 0.05-0.02 Component Material

1000 (or
7 Special -
above) Frame Mild Steel
Hollow Pipe Mild Steel
III. EQUIPMENT SET-UP
Tank Mild Steel
A schematic layout of AJM is shown in Figure The filtered
gas, supplied under pressure to the mixing chamber containing Nozzle Carbide
the abrasive powder, entrains the abrasive particle and is the Glass Clamp Mild Steel
passed into a connecting hose. This abrasive and gas mixture Coupling Standard
emerges from a small nozzle at high velocity. The abrasive
powder feed rate is controlled by the amplitude of vibration of Push Connector Standard
the mixing chamber. A pressure regulator controls the gas Tee Connector Standard
flow and pressure. The nozzle is mounted on a fixture. Either Abrasive Power Silicon Carbide
the work piece or the nozzle is moved by cams pantograph or
Air Pipe PVC
other suitable mechanisms to control the size and shape of the
cut. Hand operation is sometimes adequate to remove surface Nut Bolt Mild Steel
contaminations or in cutting where accuracy is not very Ball Lever Brass
critical. Dust removal equipment is necessary to protect the
environment. Commercial bench mounted units including all
controls, motion producing devices, and dust control TABLE III
equipment are available. The working principle is shown. PROPERTIES OF MATERIAL C45

Yield
Tensile Elong
Strengt Hard
Grad Conditio Strengt ation
h ness
e n h A5(%
R HRC
(Mpa) )
(Mpa)
Rolled
Annealed
C45 750
Water- 460 540 18 58
quenched 330 2270 30 55
1980
Oil
quenched

Material for shell selected = C45 = 0.45 % carbon.

Design pressure pi = 10 bar = 10 kg/cm2= 1 N/mm2
Material C45 0.45 % carbon
t = 540 N/mm2 take FOS 4 = 135 N/mm2
Joint efficiency of fillet welding T: 80%
Thickness of shell obtained from formulas:
Based on thick cylinder

By Circumferential stress criteria:

Fig. 1 Setup of Equipment t=(PiDi) / (2t t)
t=(180i) / (2135 0.8)
=80/216
=0.37mm
Adding corrosion allowance of 1.5mm
t=0.37+1.5=1.87mm
Let t=2mm
Value of thickness t=2mm but we are using 5mm thick
cylinder, so our design is safe.
Outer diameter of shell will be D2=80+10=90mm
B. Fabrication Procedure
We prepared cylindrical hopper from 16 gauge M.S. sheet.
A nozzle is attached at the bottom of the hopper with the
necessary provisions. Manufactured connections for pressure
gauge. Hoses are arranged to provide air supply from the
compressor to hopper and at the nozzle to mix with abrasive
particles and to create a stream of jet for machining for
pneumatic connections, nozzle and all parts are attached with
nipples of pneumatic supply which are made of brass. The
frame is manufactured by using mild steel by welding.
IV. COMPARISON TO OTHER MACHINING PROCESSES
A. Comparison with EDM
Key Precision of Wire EDM strengths
Extremely precise parts are possible [0.0001"
(0.025mm)]
Very thick parts [over 12" (30 cm)] can be made
Intentional taper can be put into a part for die clearance
and other uses
Key Precision of Abrasive jet strengths
Five to ten times faster in parts less than 1" (2.5 cm)
thick [but, at 0.003" (0.1 mm), less precise as well
No Heat Affected Zone (HAZ), so no need for secondary
operations to remove the HAZ or additional heat-treating
to compensate for it
Works well in non-conductive materials (such as glass,
stone, plastic) as well as conductive materials
Can pierce material directly without the need for a pre-
drilled starter hole
Can produce large parts at reasonable costs
Simple and rapid programming and set-up with minimal
fixturing
B. Comparing Abrasive Jet to Laser
Key Precision of laser strengths
Very fast production in thin, non-reflective materials
such as sheet steel.
Accuracy to 0.001" (0.025 mm) or better in thin
material.
Key Precision of precision abrasive jet strengths
Can produce parts up to 2" (5.1 cm) thick in virtually
any material while holding tolerances on the order of
0.003" to 0.005" (0.08 to 0.1 mm).
Can machine reflective, conductive and thicker materials
such as stainless steel and aluminum, copper and brass.
Cuts without melting, providing a smooth uniform
surface with very little burr or dross.
No heat-affected zone (HAZ), which may eliminate the
need for a secondary operation to remove HAZ and
makes conventional secondary operations, such as
reaming or tapping, easier to perform.
No noxious gas or vapors produced during cutting.
Simple and rapid programming and set-up for short-run
parts.
C. Comparison of Precision Abrasive Jet to Milling
Key Precision of mill or machining center strengths
A well-understood familiar technology.
Able to make three-dimensional parts.
Rapid production if set up and programmed for long-run
parts.
Key Precision of abrasive jet strengths
Very rapid programming and set-up does not require a
highly trained operator.
Very low cutting loads mean that fixturing is easier and
also means that intricate and delicate parts can be
machined.
One cutting tool performs all machining functions in all
materials, so there is no need to purchase and calibrate
multiple cutting tools.
Large cutting envelope compared to a machining center
of comparable price.
Minimal burr compared to conventional machining.
Environmentally friendly; no oil-soaked chips and
minimal scrap.
The key reasons traditional job shops buy a precision
abrasive jet is to get new projects, become more
competitive, and make more money.
V. OBSERVATION
Work material: Glass
Abrasive: SiO
Particle Size: 200 Mesh
Abrasive Flow Rate: 10gm /min
Stand of distance: 3mm
Fig. 2 Effect of Pressure On Material Removal Rate
A. Brief Observation ACKNOWLEDGMENT
TABLE II
BRIEF OBSERVATION
We would first like to thank my thesis advisor Miss Shweta
V. Matey of the Lokmanya Tilak College of Engineering,
Grain Size (in Kopar Khairane affiliated with Mumbai University. The door
Sr. No Abrasive Type
Microns) to Prof. Shweta V. Matey office was always open whenever
1 Medium Air we ran into a trouble spot or had a question about our research
or writing. She consistently allowed this paper to be our own
SiO (100-200 work, but steered us in the right the direction whenever he
2 Abrasive
microns)
thought we needed it.
3 Pressure 2-10 kg/cm2
REFERENCES
4 Nozzle Size 0.05-1 mm
[1] Behringer -Plosonka, Catherine A., "Abrasive jet Cutting
Carbide
5 Material of Nozzle - A Technology Afloat on a Sea of Potential",
Manufacturing Engineering, Vol. 99, Nov. 1987, pp. 37-
6 Nozzle Work Distance 0.25-15 mm 41.
[2] Haylock, Rob, "Abrasive jet Cutting", Conference:
Automach Australia "85, July 2-5, 1985, Melbourne,
Australia.
VI. CONCLUSIONS [3] Slattery, Thomas J., "Abrasive Jet Carves Out
According to the various research papers available till date, Metalworking Niche", Machine and Tool Blue Book,
lot of work has done on abrasive particles and its geometry, July 1991, pp. 31-34.
different process parameters, volume of material removal [4] Hitchox, Alan L., "Vote of Confidence for Abrasive Jet
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factor review of the research and development in the AJM has Flow International, 1995.
been conducted in this paper. It was shown that AJM process [5] Steinhauser, John, "Abrasive jets: on the Cutting Edge
is receiving more and more attention in the machining areas, of Technology", Flow Systems, Inc.
particularly for the processing of difficult-to-cut materials. Its [6] Ayers, Gary W., "Principles of Abrasive Jet Cutting",
unique advantages over other conventional and un- Tappi Journal, Vol. 70, Sept 1993, pp. 91-94.
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of abrasive flow rate on performance characteristics. Hence Conference, Aug. 1989.
there is scope for improvement for the study of effect of [8] Hashish, M., "Steel Cutting with Abrasive jets", 6th
abrasive flow rate on performance characteristics like material International Symposium on Jet Cutting Technology,
removal rate and taper angle. Improper mixing chamber April 1982.
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stratification, powder compaction, powder humidification etc. Abrasive jets for Medical Applications", 5th American
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