Skip to main content
SpringerLink
Log in

Finishing force analysis and simulation of nanosurface roughness in abrasive flow finishing process using medium rheological properties

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Surface roughness plays a vital role in functional requirements of a component. Abrasive flow finishing (AFF) is an advanced finishing process used to achieve micro/nanolevel surface finish in complex geometries, internal inaccessible pathways made up of difficult to finish material, etc. In order to control the process and improve its performance, it is important to understand the mechanism of finishing. In this paper, an attempt has been made to model the forces generated during AFF process using the rheological properties of the viscoelastic medium used in the process. Secondly, by using the calculated forces, simulation of the final surface roughness profile of the workpiece has been presented. The simulated results are in good agreement with the experimental results.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Rhoades L (1991) Abrasive flow machining: a case study. J Mater Process Technol 28:107–116

    Article  Google Scholar 

  2. JainV K (2002) Advanced machining process. Allied Publishers, New Delhi

    Google Scholar 

  3. Loveless TR, Williams RE, Rajurkar KP (1994) A study of the effects of abrasive flow finishing on various machined surfaces. J Mater Process Technol 47:133–151

    Article  Google Scholar 

  4. Jain RK, Jain VK, Dixit PM (1999) Modelling of material removal and surface roughness in abrasive flow machining process. Int J Mach Tools Manuf 39:1903–1923

    Article  Google Scholar 

  5. Jain RK, Jain VK (2003) Finite element simulation of abrasive flow machining. Proc IMechE Part B J Eng Manuf 217:1723–1726

    Article  Google Scholar 

  6. Jain RK, Jain VK (1999) Simulation of surface generated in abrasive flow machining process. Robot Comput Integr Manuf 15:403–412

    Article  Google Scholar 

  7. Jain RK, Jain VK (2004) Stochastic simulation of active grain density in abrasive flow machining. J Mater Process Technol 152:17–22

    Article  Google Scholar 

  8. Gorana VK, Jain VK, Lal GK (2004) Experimental investigation into cutting forces and active grain density during abrasive flow machining. Int J Mach Tools Manuf 44:201–211

    Article  Google Scholar 

  9. Gorana VK, Jain VK, Lal GK (2006) Prediction of surface roughness during abrasive flow machining. Int J Adv Manuf Technol 31:258–267

    Article  Google Scholar 

  10. Gorana VK, Jain VK, Lal GK (2006) Forces prediction during material deformation in abrasive flow machining. Wear 260:128–139

    Article  Google Scholar 

  11. Walia RS, Shan HS, Kumar PK (2006) Finite element analysis of media used in the centrifugal force assisted abrasive flow machining process. Proc IMechE Part B J Eng Manuf 220:1775–1785

    Article  Google Scholar 

  12. Reddy MK, Sharma AK, Kumar P (2008) Some aspects of centrifugal force assisted abrasive flow machining of 2014 Al alloy. Proc IMechE Part B J Eng Manuf 222:773–783

    Article  Google Scholar 

  13. Sadiq A, Shunmugam MS (2009) Magnetic field analysis and roughness prediction in magnetorheological abrasive honing (MRAH). Mach Sci Technol Int J 13:246–268

    Article  Google Scholar 

  14. Das M, Jain VK, Ghoshdastidar PS (2008) Analysis of magnetorheological abrasive flow finishing (MRAFF) process. Int J Adv Manuf Technol 38:613–621

    Article  Google Scholar 

  15. Das M, Jain VK, Ghoshdastidar PS (2008) Fluid flow analysis of magnetorheological abrasive flow finishing (MRAFF) process. Int J Mach Tools Manuf 48:415–426

    Article  Google Scholar 

  16. Das M, Jain VK, Ghoshdastidar PS (2015) A 2D CFD simulation of MR polishing medium in magnetic field-assisted finishing process using electromagnet. Int J Adv Manuf Technol 76:173–187

    Article  Google Scholar 

  17. Chen KY, Cheng KC (2014) A study of helical passageways applied to polygon holes in abrasive flow machining. Int J Adv Manuf Technol 74:781–790

    Article  Google Scholar 

  18. Wan S, Ang YJ, Sato T, Lim GC (2014) Process modeling and CFD simulation of two-way abrasive flow machining. Int J Adv Manuf Technol 71:1077–1086

    Article  Google Scholar 

  19. Hull JB, Sullivan DO, Fletcher AJ, Trengove SA, Mackie J (1992) Rheology of carrier media used in abrasive flow machining. Key Eng Mater 72-74617-626

  20. Davies PJ, Fletcher AJ (1995) The assessment of the rheological characteristics of various polyborosilixane/grit mixtures as utilized in the abrasive flow machining. Proc IMechE Part C J Mech Eng Sci 209:409–418

    Article  Google Scholar 

  21. Fletcher AJ, Fioravanti A (1996) Polishing and honing processes: an investigation of the thermal properties of mixtures of polyborosiloxane and silicon carbide abrasive. Proc IMechE Part C J Mech Eng Sci 210:255–266

    Article  Google Scholar 

  22. Jain VK, Ranganatha C, Muralidhar K (2001) Evaluation of rheological properties of medium for AFM process. Mach Sci Technol 5:151–170

    Article  Google Scholar 

  23. Wang AC, Liu CH, Liang KZ, Pai SH (2007) Study of the rheological properties and the finishing behavior of abrasive gels in abrasive flow machining. J Mech Sci Technol 21:1593–1598

    Article  Google Scholar 

  24. Kar KK, Ravikumar NL, Tailor PB, Ramkumar J, Sathiyamoorthy D (2009) Performance evaluation and rheological characterization of newly developed butyl rubber based media for abrasive flow machining process. J Mater Process Technol 209:2212–2221

    Article  Google Scholar 

  25. Kar KK, Ravikumar NL, Tailor PB, Ramkumar J, Sathiyamoorthy D (2009) Preferential media for abrasive flow machining. J Manuf Sci Eng 131:011009.1–011009.12

    Article  Google Scholar 

  26. Sankar MR, Jain VK, Ramkumar J, Joshi YM (2011) Rheological characterization of styrene-butadiene based medium and its finishing performance using rotational abrasive flow finishing process. Int J Mach Tools Manuf 51:947–957

    Article  Google Scholar 

  27. Sidpara A, Das M, Jain VK (2009) Rheological characterization of magnetorheological finishing fluid. Mater Manuf Process 24:1467–1478

    Article  Google Scholar 

  28. Sidpara A, Jain VK (2014) Rheological properties and their correlation with surface finish quality in MR fluid-based finishing process. Mach Sci Technol Int J 18:367–385

    Article  Google Scholar 

  29. Macosko CW (1994) Rheology principles, measurements and applications. VCH Publishers, Inc

  30. Sankar MR, Jain VK, Ramkumar J (2009) Experimental investigation and mechanism of material removal in nano finishing of MMCs using abrasive flow finishing (AFF) process. Wear 266:688–698

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati, 781 039, India

    Sachin Singh & M. Ravi Sankar

  2. Department of Production Engineering, National Institute of Technology Trichy, Trichy, 620 015, India

    A. S. Arjun Raj

  3. Department of Mechanical Engineering, Indian Institute of Technology Kanpur, Kanpur, 208 016, India

    V. K. Jain

Authors
  1. Sachin Singh
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. A. S. Arjun Raj
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. M. Ravi Sankar
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. V. K. Jain
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to M. Ravi Sankar.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Singh, S., Raj, A.S.A., Sankar, M.R. et al. Finishing force analysis and simulation of nanosurface roughness in abrasive flow finishing process using medium rheological properties. Int J Adv Manuf Technol 85, 2163–2178 (2016). https://doi.org/10.1007/s00170-015-8333-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-015-8333-2

Keywords

Search

Navigation