Abstract
This study developed a self-modulating abrasive medium whose viscosity and fluidity can be adjusted during the processing period. The complex micro channel was fabricated on the stainless steel (SUS304) by using wire electrical discharge machining (wire-EDM). An experiment of employing abrasive flow machining (AFM) was conducted to evaluate the characteristics of various levels of roughness and finishing of the micro channel surface. In the experiment, the parameters of affecting AFM machining including abrasive particle size, concentration, extrusion pressure and machining time were selected to verify the machining quality of the micro channel.
Experimental results reveal that at high viscosity and concentration the surface roughness of a medium with a coarse particle size is lower than that of a medium with a fine particle size. Furthermore, the machining quality of the micro channel improves as the extrusion pressure and the machining time increase because there is an increase in the fluidity of the medium. Therefore, the self-modulating abrasive-laden medium can be used to determine and influence the surface finishing and the precision of the shapes.
Similar content being viewed by others
References
Yan BH, Lin YC, Huang FY (2002) Surface modification of Al-Zn-Mg alloy by combined electrical discharge machining with ball burnish machining. Int J Mach Tools Manuf 42:925–934
Wang AC, Yan BH, Li XT, Huang FY (2002) Use of micro ultrasonic vibration lapping to enhance the precision of microholes drilled by micro electro-discharge machining. Int J Mach Tools Manuf 42:915–923
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
Jain VK, Adsul SG (2000) Experimental investigations into abrasive flow machining (AFM). Int J Mach Tools Manuf 40:1003–1021
Jain RK, Jain VK (2004) Stochastic simulation of active grain density in abrasive flow machining. J Mater Process Technol 152:17–22
Jain RK, Jain VK (2001) Specific energy and temperature determination in abrasive flow machining process. Int J Mach Tools Manuf 41:1689–1704
Jain RK, Jain VK (2000) Optimum selection of machining conditions in abrasive flow machining using neural network. J Mater Process Technol 108:62–67
Petri KL, Billo RE, Bidanda B (1998) A neural network process model for abrasive flow machining operations. J Manuf Syst 17(1):52–64
Haan JJ, Steif PS (1998) Abrasive wear due to the flow of a concentrated suspension. Wear 219:177–183
Acknowledgement
The authors would like to thank the National Science Council of the Republic of China for financially supporting this research under Contract No. NSC 93-2212-E- 008-021.
Author information
Authors and Affiliations
Corresponding author
Additional information
This paper has not been published nor has it been submitted for publication elsewhere.
Rights and permissions
About this article
Cite this article
Tzeng, HJ., Yan, BH., Hsu, RT. et al. Self-modulating abrasive medium and its application to abrasive flow machining for finishing micro channel surfaces. Int J Adv Manuf Technol 32, 1163–1169 (2007). https://doi.org/10.1007/s00170-006-0423-8
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-006-0423-8