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Process modeling and CFD simulation of two-way abrasive flow machining

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Abstract

The present study examines a simple, zero-order semi-mechanistic approach towards the analysis of the two-way flow abrasive flow machining process, stemming from a need to reduce the number of time-consuming and labor-intensive experimental trials. The description consists of a set of coupled models, which are the following: an inelastic non-Newtonian model to capture the flow behavior of the abrasive media; a wall slip model, as a function of wall shear-rate, to calculate the relative motion between the media and the confining wall; and a previously derived process model describing surface roughness and stock removal evolution. Predicted results were benchmarked against experimental ones obtained from studies on straight tubes with ellipsoidal cross-sections. We end this report with an application example illustrating a method to produce uniform finishing of a tube hole with complex cross-section geometry.

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Authors and Affiliations

  1. Institute of High Performance Computing, 1 Fusionopolis Way, #16-16 Connexis North, Singapore, 138632, Singapore

    S. Wan

  2. Singapore Institute of Manufacturing Technology, 71 Nanyang Drive, Singapore, 638075, Singapore

    Y. J. Ang, T. Sato & G. C. Lim

Authors
  1. S. Wan
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  2. Y. J. Ang
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  3. T. Sato
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  4. G. C. Lim
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Correspondence to S. Wan.

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Wan, S., Ang, Y.J., Sato, T. et al. Process modeling and CFD simulation of two-way abrasive flow machining. Int J Adv Manuf Technol 71, 1077–1086 (2014). https://doi.org/10.1007/s00170-013-5550-4

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  • DOI: https://doi.org/10.1007/s00170-013-5550-4

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