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Rheological characterisation of abrasive media and finishing behaviours in abrasive flow machining

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Abstract

Flow field simulation of abrasive media in a constrained passage in abrasive flow machining (AFM) plays a decisive role in optimising process parameters and designing the core of a fixture. Based on the experimental rheological characterisation of various types of abrasive media, a model of flow field simulation of abrasive media was constructed by combining with the continuous medium hypothesis. Moreover, a pressure detection platform was built for the constrained passage and test and simulated data were compared and analysed. The results demonstrate that the diameter of abrasives slightly affects the rheological characterisation of abrasive media under the same mass fraction, and rheological characterisation of abrasive media before and after use obeys a power-law constitutive model. Simulated pressures in the flow field show a completely consistent trend with measured pressures although they deviate significantly in the inlet region. Pressure in the constrained passage increases with increasing extrusion pressure and gradually attenuates along the flow direction, so that abrasive finishing marks become shallower along the flow direction. In addition, the increased extrusion pressure increases the final surface roughness of the polished surface and extends the processing time required to stabilise the final surface quality.

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Acknowledgements

The authors appreciate the anonymous reviewers for their constructive comments and suggestions.

Funding

This work was supported by the Guangdong Basic and Applied Basic Research Foundation (Grant No. 2019A1515010720), NSFC-Guangdong Joint Fund Project (Grant No. U1801259), Creative Research Groups of NSFC (Grant No. 51621064), National Natural Science Foundation of China (Grant No. U1708256), and Fundamental Research Funds for the Central Universities (Grant Nos. DUT17ZD201, DUT18GF104).

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Authors and Affiliations

  1. School of Electromechanical Engineering, Guangdong University of Technology, Guangzhou, 510006, China

    Youzhi Fu & Qiusheng Yan

  2. Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian, 116024, China

    Hang Gao & Xuanping Wang

  3. Key Laboratory of Special Purpose Equipment and Advanced Processing Technology of Ministry of Education, Zhejiang University of Technology, Hangzhou, 310024, China

    Xu Wang

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  1. Youzhi Fu
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Correspondence to Youzhi Fu or Hang Gao.

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Fu, Y., Gao, H., Yan, Q. et al. Rheological characterisation of abrasive media and finishing behaviours in abrasive flow machining. Int J Adv Manuf Technol 107, 3569–3580 (2020). https://doi.org/10.1007/s00170-020-05288-9

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  • DOI: https://doi.org/10.1007/s00170-020-05288-9

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