An experimental investigation of abrasive jet machining parameters for optimized surface finish of mild steel components

Abstract

Abrasive jet machining is one of the unconventional machining processes that are initiated for alternations of surface characteristics of ductile materials, like mild steel, due to the entrainment of high-velocity abrasive particles. The present experimental investigation deals with the major process parameters of the AJM process, namely air pressure, standoff distance, and time of machining, on the average surface roughness (Ra) of mild steel specimens. Experiments were conducted on the self-developed AJM setup using aluminum oxide abrasive particles of an average size of 50 µm. The pressure of air is changed in three levels, 6, 7, and 8 bars. The standoff distance is taken as 2 mm constant for all the cases. The surface roughness was measured at machining times of 20, 40, and 45 seconds. The presence of the increase of air pressure from 6 to 8 bars applied for all the machining time showed an increasing influence on roughness, although always significant in Ra. For 8 bars of pressure and 45 s of machining, the minimum resulted in 1.39 µm, compared with 3.47-4.02 µm. The rate of decrease in surface roughness is sharp with increasing machining time from 20 to 40 seconds but marginal beyond that. An optimal machining time of 40–45 seconds was identified to obtain a minimum Ra. Capability of AJM as an effective technique to enhance the surface finish of mild steel components, and practical insight of this study is very useful toward optimization of process parameters for attaining the targeted surface quality. The results obtained may assist in expanding the industrial application of AJM toward the finishing of ductile materials in various manufacturing fields.