scholarly journals Various developments in Abrasive Flow Machining Process: A Review

2019 ◽  
Vol 4 (2) ◽  
Author(s):  
Parvesh Ali ◽  
Ranganath M. S ◽  
R.S Walia ◽  
Q. Murtaza
Keyword(s):  
Surface Finish ◽  
Material Removal ◽  
Abrasive Particle ◽  
Machining Process ◽  
Complex Geometries ◽  
Major Objective ◽  
Workpiece Surface ◽  
Abrasive Particles ◽  
Abrasive Flow Machining ◽  
Recent Developments

Abrasive flow machining is a nonconventional process used for polishing of metallic components, internal inaccessible cavities or recesses using a semi liquid paste. It was developed to deburr, polish the surfaces having complex geometries and edges by flowing abrasive particles with a visco-elastic nonconductive media over them. Abrasive particle sharp cutting edges remove the material by abrasion mechanism from the workpiece surface. In the recent year, work has been carryout towards the development of abrasive flow machining for achieving the higher material removal and improved surface finish. This method has a unique property of simultaneous improvement in material removal and surface finish. In this paper authors discussed about various recent developments in abrasive flow machining with major objective of improving the productivity of the process.

Development of the improved Preston equation for abrasive flow machining of aerofoil structures and components

2018 ◽  
Vol 233 (9) ◽  
pp. 1397-1404 ◽  
Author(s):  
Kai Cheng ◽  
Yizhi Shao ◽  
Mitul Jadva ◽  
Rodrigo Bodenhorst
Keyword(s):  
Surface Roughness ◽  
Material Removal ◽  
Machining Process ◽  
Dynamics Simulation ◽  
Abrasive Machining ◽  
Abrasive Particles ◽  
Abrasive Flow Machining ◽  
Flow Features ◽  
The Media ◽  
Experimental Trials

The paper presents an improved Preston equation, which aims to be part of the industrial application to abrasive flow machining. The equation will aid the engineers to optimise the process for desired surface roughness and edge tolerance characteristics on complex geometries in an intuitive and scientific manner. The methodology presented to derive the equation underpins the fundamental cutting mechanics of abrasive machining or polishing assuming all abrasive particles within the media are spherical as manufacturers defined. Further to derivation, full four factorial experimental trials and computational fluid dynamics simulation are implemented to generate the flow features of media on coupon to evaluate and validate the equation for its competency and accuracy on prediction of material removal. The modified Preston equation can significantly contribute to optimise the abrasive flow machining process, and will advantage the integrated machine design to predict better virtual surface roughness and material removal rates.

Experimental characterization of conformal hydrodynamic nanopolishing of a machined single crystal sapphire cavity

2021 ◽  
pp. 251659842110153
Author(s):  
Prashant Kumar ◽  
Rinku Mittal ◽  
Ramesh K. Singh ◽  
Suhas S. Joshi
Keyword(s):  
Particle Size ◽  
Single Crystal ◽  
Surface Finish ◽  
Abrasive Particle ◽  
Diamond Turning ◽  
Initial Surface ◽  
Workpiece Surface ◽  
Abrasive Particles ◽  
Single Crystal Sapphire

Sapphire is an important ceramic material which finds applications in fields such as temperature sensing, optics, electronics, and ceramic bearings. Polishing of sapphire has always been a difficult task for industries and research communities. Hydrodynamic polishing (HDP) is one of the prominent methods used for polishing of hard and profiled surfaces, whereas rigid tool-based methods such as diamond turning, grinding, and honing have many limitations. The HDP process involves deterministic flow of abrasive particles in the slurry between the workpiece surface and a rotating soft tool to obtain the desired surface finish. A novel experimental setup has been fabricated to realize the conformal hydrodynamic nanopolishing on single crystal sapphire cavity. In this study, the experiments were conducted to understand the effect of abrasive particle size, basicity of slurry, and change in temperature of slurry on the polishing of machined sapphire cavity. The effect of the initial surface roughness of the machined cavity on conformal hydrodynamic nanopolishing has also been investigated. A microcrack/pit-free surface has been found after the final polishing of the sapphire cavity. An improvement of 21% is found in surface finish after the final polishing using abrasive particle size of 0.06 µm. Abrasive slurry with higher basicity (pH 13) does not improve the surface finish. By heating the abrasive slurry to a temperature of 70°C–75°C, surface finish improves by ∼26% as compared to improvement of ∼ 21% at room temperature polishing.

Material Removal and Application by Chemical Impact Reaction in Nano-Abrasive Jet Polishing

2013 ◽  
Vol 631-632 ◽  
pp. 550-555
Author(s):  
Wen Qiang Peng ◽  
Sheng Yi Li ◽  
Chao Liang Guan ◽  
Xin Min Shen
Keyword(s):  
Material Removal ◽  
Abrasive Particle ◽  
Precision Machining ◽  
Optical Surface ◽  
Polishing Process ◽  
Abrasive Particles ◽  
Mechanical Process ◽  
Abrasive Jet Polishing ◽  
Ultra Precision ◽  
Machining Properties

Material removed by mechanical process inevitably causes surface or subsurface damage containing cracks, plastic scratch, residual stress or dislocations. In nano-abrasive jet polishing (NAJP) the material is removed by chemical impact reaction. The chemical impact reaction is validated by contrast experiment with traditional lap polishing process in which the material is mainly removed through mechanical process. Experiment results show the dependence of the abrasive particles on the choice of materials. Even if the abrasive particle and the workpiece are composed of similar components, the machining properties are remarkably different due to slight differences in their physical properties or crystallography etc. Plastic scratches on the sample which was polished by the traditional mechanical process are completely removed by NAJP process, and the surface root-square-mean roughness has decreased from 1.403nm to 0.611nm. The NAJP process will become a promising method for ultra precision machining method for ultrasmooth optical surface.

Parametric Optimization of Magnetic Abrasive Finishing Using Adhesive Magnetic Abrasive Particles

2019 ◽  
Vol 7 (2) ◽  
pp. 34-47
Author(s):  
Palwinder Singh ◽  
Lakhvir Singh ◽  
Arishu Kaushik
Keyword(s):  
Surface Finish ◽  
Medical Equipment ◽  
Material Removal ◽  
Parametric Optimization ◽  
Removal Rate ◽  
Improvement Rate ◽  
Magnetic Abrasive Finishing ◽  
Abrasive Particles ◽  
Abrasive Finishing ◽  
Depth Analysis

A very precise surface finish is desirable in manufacturing semiconductors, medical equipment, and aerospace parts. The examinations on magnetic abrasive finishing (MAF) processes are being done for the modern industry. This newly developed process is serving the industry to achieve the desired level of precision and surface finish. This research represents the MAF of aluminum pipes using adhesive magnetic abrasive particles. The different process parameters were optimized using the Response Surface Methodology (RSM) method to gain an in-depth analysis of surface roughness in terms of roughness improvement rate (RIR), and material removal rate (MRR). The achieved maximum RIR and MRR was 81.49% and 2.74mg/min, respectively. The finished workpieces were microscopically investigated by scanning electron microscopy (SEM) to further study the mechanism of MAF process.

Analysis of finishing forces and surface finish during magnetorheological abrasive flow finishing of asymmetric workpieces

2019 ◽  
Vol 2 (2) ◽  
pp. 133-151 ◽  
Author(s):  
Jayant ◽  
V. K. Jain
Keyword(s):  
Magnetic Field ◽  
Surface Finish ◽  
Research Work ◽  
Workpiece Surface ◽  
Abrasive Particles ◽  
Wear And Tear ◽  
Frictional Forces ◽  
Spatially Varying ◽  
Final Surface Finish ◽  
Abrasive Flow Finishing

Magnetorheological abrasive flow finishing (MRAFF) is an advanced hybrid process for producing ultrafine finished surfaces. Such surfaces reduce frictional forces and thereby minimize wear and tear to increase functional lifetime of the components. In the present research work, a model has been developed for simulating the results of MRAFF process. First, magnetic field is simulated and then a detailed study on the rheology of the magnetorheological polishing (MRP) fluid is conducted to develop a viscosity model for the flow of non-Newtonian shear thinning fluid. To calculate the forces acting in the process of material removal, the flow of MRP fluid around an asymmetric workpiece (knee joint) in a spatially varying magnetic field is simulated. Finishing forces exerted by the abrasive particles on the workpiece surface are analysed to develop a model for predicting surface roughness. A methodology has been proposed to evolve a variable correction factor to determine active abrasive particles at different locations on the workpiece surface for accurate simulation of surface finish operation. It is found that the magnetic field greatly influences the process performance by governing the viscosity of the MRP fluid and the distribution of the abrasive particles in the medium. During finishing of an asymmetric workpiece, the surface finish obtained at different locations on the workpiece surface is different. The developed model is capable to predict final surface finish within the acceptable accuracy when compared with the experimental results.

On the Development of an Experimental Testing Platform for the Vortex Machining Process

2013 ◽  
Vol 135 (5) ◽  
Author(s):  
Stephen C. Howard ◽  
Jacob W. Chesna ◽  
Stuart T. Smith ◽  
Brigid A. Mullany
Keyword(s):  
Material Removal ◽  
Closed Loop ◽  
Experimental Testing ◽  
Machining Process ◽  
Gaussian Shape ◽  
Workpiece Surface ◽  
Loop Control ◽  
Height Control ◽  
Stability Issues ◽  
Process Controls

The development of an experimental platform for studying Vortex Machining is presented. This process uses oscillating probes to generate localized vortices in polishing slurry in a region near to a workpiece surface. These vortices create material removal footprints having lateral dimensions typically measuring tens of micrometers. From studies of the process variables and subsequent machining footprints a number of process controls have been implemented and are discussed herein. These include a localized metrology frame to control specimen to probe position, coarse-fine translation axes for submicrometer motion control, closed-loop control of probe oscillation, and a slurry height control system. To illustrate the fidelity of these additional controls, the evolution from early machining footprints to the recent production of footprint arrays are presented. While process stability issues remain, machining footprints of near Gaussian shape having dimensions of 10–20 μm diameter and 40 nm depth after machining for 30 min can be reproduced.

Enhancing the Surface Quality by Iso Pulse Generator in EDM Process

2012 ◽  
Vol 622-623 ◽  
pp. 380-384 ◽  
Author(s):  
T. Muthuramalingam ◽  
B. Mohan
Keyword(s):  
Surface Finish ◽  
Material Removal ◽  
Pulse Generator ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
Machining Process ◽  
Discharge Energy ◽  
Crater Volume ◽  
Machining Characteristics ◽  
Edm Process

In automobile and aeronautical industries, complex moulds and dies is produced by Electrical Discharge Machining process. The surface finish is determined by the crater volume in EDM process. The amount of crater volume is influenced by the amount and distribution of discharge energy. The discharge energy is directly proportional to the average discharge current. This amount of current is determined by the duration of discharging effect. This study deals about evaluating the performance of iso current pulse generator on machining characteristics in EDM. Due to its ability of reducing stochastic nature in EDM process, iso pulse generator could produce better surface finish than conventional transistor pulse train generator with higher material removal rate.

Study on Effect of Viscoelastic Properties on Surface Roughness Uniformity in Abrasive Flow Machining for Plate Surface

2016 ◽  
Vol 1136 ◽  
pp. 131-134 ◽  
Author(s):  
Xuan Ping Wang ◽  
You Zhi Fu ◽  
Hang Gao
Keyword(s):  
Viscoelastic Properties ◽  
Material Removal ◽  
Flow Direction ◽  
Dominant Role ◽  
Machining Process ◽  
Rheological Parameters ◽  
Process Conditions ◽  
Abrasive Flow Machining ◽  
Surface Polishing ◽  
Viscoelastic Constitutive Model

Abrasive flow machining is a suitable technique for surface polishing due to its rheological characteristics, however, it's difficult to achieve uniform roughness for polished surfaces as the material removal mechanism is still ambiguous. In this paper the viscoelastic properties of abrasive flow media are incorporated to explore the phenomena of inconsistent material removal in the AFM polishing process, where the material removal near the edges is obviously higher than that in the middle along the flow direction. The rheological parameters of the viscoelastic constitutive model adopted are varied to study the polishing effectiveness under different process conditions. The results of numerical analysis reveal that there exist distinct differences of viscoelastic stress fields between the edges and the middle regions, which leads to the material removal near the edges is higher than that in the middle. It could be concluded that the viscoelastic properties of abrasive media play the dominant role for the inconsistent material removal in abrasive flow machining process.

Study on machining mechanism of high viscoelastic abrasive flow machining for surface finishing

2016 ◽  
Vol 231 (4) ◽  
pp. 608-617 ◽  
Author(s):  
Zhiguo Dong ◽  
Gang Ya ◽  
Jiancheng Liu
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Experimental Tests ◽  
Normal Pressure ◽  
Machining Process ◽  
Surface Finishing ◽  
Abrasive Flow Machining ◽  
Machining Mechanism ◽  
Flow Pressure

Abrasive flow machining is a pragmatic machining process used for part finishing. This article primarily focuses on the study of machining mechanism of high viscoelastic abrasive flow machining, with the aim to understand the relation among the abrasive media’s flow pressure, the material removal rate and the machining quality. The theoretical calculation models of the normal pressure on the inner surface of a circular tube and the wall sliding velocity are established based on rheology theory. The material removal rate of abrasive flow machining with a high viscoelastic abrasive media is derived. Numerical simulations with various machining conditions were conducted using the mathematical models proposed in this research and the obtained findings are discussed. The feasibility of these models introduced for high viscoelastic abrasive machining is also investigated and verified through actual experimental tests.

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