Skip to main content
Log in

Experimental investigations into ultrasonic-assisted abrasive flow machining (UAAFM) process

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

Abstract

Ultrasonic-assisted abrasive flow machining (UAAFM) process is being investigated as an effective variant of traditional abrasive flow machining process. This process aims to achieve better surface finish at higher finishing rate. In this process, a relatively high frequency (5–20 kHz) is provided to the workpiece externally using a piezo actuator. This additional effect is also termed as ultrasonic assistance. Owing to this, the abrasives present in the medium hit the workpiece asperities mostly at an angle and at a higher resultant velocity, thereby making them more effective. In the present work, experiments were conducted on EN8 steels (AISI 1040) to evaluate the process performance of UAAFM on the double acting horizontal type setup. Response surface methodology (RSM) technique was used for designing the experimental plan with four input parameters—applied frequency, extrusion pressure, abrasive mesh size, and processing time. The results obtained after machining by UAAFM were also compared with traditional AFM process. It was found that significant improvements in surface finish could be recorded in UAAFM. The maximum percentage improvement achieved in surface finish was 81.02 %, while maximum improvement in material removal was 0.05 %. The machined surfaces were also investigated using different characterization tools such as scanning electron microscope (SEM), X-ray diffractometer, and three-dimensional optical profilometer.

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

Access this article

Subscribe and save

Springer+ Basic
EUR 32.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or Ebook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

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

Instant access to the full article PDF.

Similar content being viewed by others

References

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

    Article  Google Scholar 

  2. Rhoades LJ (1988) Abrasive flow machining. Manuf Eng 1:75–78

  3. Loveless TR, Willams 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. Cheema MS, Venkatesh G, Dvivedi A, Sharma AK (2012) Developments in abrasive flow machining: a review on experimental investigations using abrasive flow machining variants and media. Proc ImechE B J Eng Manuf 226(12):1951–1962

    Article  Google Scholar 

  5. Mali HS, Manna A (2009) Current status and application of abrasive flow finishing processes: a review. Proc ImechE B J Eng Manuf 223(7):809–820

    Article  Google Scholar 

  6. Singh S, Shan HS, Kumar P (2002) Wear behavior of materials in magnetically assisted abrasive flow machining. J Mater Process Technol 128(1):155–161

    Article  Google Scholar 

  7. Sidpara A, Jain VK (2011) Experimental investigations into forces during magnetorheological fluid based finishing process. Int J Mach Tools Manuf 51(4):358–362

    Article  Google Scholar 

  8. Jha S, Jain VK (2004) Design and development of the magnetorheological abrasive flow finishing process. Int J Mach Tools Manuf 44(10):1019–1029

    Article  Google Scholar 

  9. Walia RS, Shan HS, Kumar P (2006) Abrasive flow machining with additional centrifugal force applied to the media. Mach Sci Technol 10(3):341–354

    Article  Google Scholar 

  10. Sankar MR, Mondal S, Ramkumar J, Jain VK (2009) Experimental investigations and modelling of drill bit guided abrasive flow finishing process. Int J Adv Manuf Technol 42:678–688

    Article  Google Scholar 

  11. Sankar MR, Ramkumar J, Jain VK (2009) Experimental investigations into rotating workpiece abrasive flow finishing. Wear 267:43–51

    Article  Google Scholar 

  12. Sharma AK, Kumar P, Rajesha S (2011) An improved ultrasonic abrasive flow machining and a device therefor. Patent number 3578/DEL/201, India, Dec 9

  13. Liu K et al (2004) Study of ductile mode cutting in grooving of tungsten carbide with and without ultrasonic vibration assistance. Int J Adv Manuf Technol 24(6):389–394

    Article  MathSciNet  Google Scholar 

  14. Kei-Lin K, Chung-Chen T (2012) Rotary ultrasonic-assisted milling of brittle materials. Trans Nonferrous Metals Soc China 22:793–800

    Article  Google Scholar 

  15. Brehl DE, Dow TA (2008) Review of vibration-assisted machining. Precis Eng 32(3):153–172

    Article  Google Scholar 

  16. Nath C, Rahman M (2008) Effect of machining parameters in ultrasonic vibration cutting. Int J Mach Tools Manuf 48:965–974

    Article  Google Scholar 

  17. Nath C, Rahman M, Andrew SSK (2007) A study on ultrasonic vibration cutting of low alloy steel. J Mater Process Technol 192:159–165

    Article  Google Scholar 

  18. Kim JD, Choi IH (1997) Micro surface phenomena of ductile cutting in the ultrasonic vibration cutting of optical plastics. J Mater Process Technol 68(1):89–98

    Article  Google Scholar 

  19. Komanduri R, Von Turkovich BF (1981) New observations on the mechanism of chip formation when machining titanium alloys. Wear 69:179–188

    Article  Google Scholar 

  20. Deyuan Z, Wang L (1998) Investigation of chip in vibration drilling. Int J Mach Tools Manuf 38:165–716

    Article  Google Scholar 

  21. Jones AR, Hull JB (1998) Ultrasonic flow polishing. Ultrasonics 36:97–101

    Article  Google Scholar 

  22. Rajesha S (2011) Some studies to enhance the capabilities of abrasive flow machining process. Dissertation, IIT Roorkee, India

  23. Venkatesh G (2010) Performance study of a new polymer media for AFM. Dissertation, IIT Roorkee, India

  24. Montgomery DC (2004) Design and analysis of experiment. Wiley, New York, pp 427–500

    Google Scholar 

  25. Reddy KM, Sharma AK, Kumar P (2008) Some aspects of centrifugal force assisted abrasive flow machining of 2014 Al alloy. Proc ImechE B J Eng Manuf 222(7):773–783

    Article  Google Scholar 

  26. Walia RS, Shan HS, Kumar P (2008) Morphology and integrity of surfaces finished by centrifugal force assisted abrasive flow machining. Int J Adv Manuf Technol 39:1171–1179

    Article  Google Scholar 

  27. Balart MJ, Bouzina A, Edwards L, Fitzpatrick ME (2004) The onset of tensile residual stresses in grinding of hardened steels. Mater Sci Eng A 367(1):132–142

    Article  Google Scholar 

  28. Poggie RA, Wert JJ (1991) The influence of surface finish and strain hardening on near-surface residual stress and the friction and wear behavior of A2, D2 and CPM-10 V tool steels. Wear 149(1):209–220

    Article  Google Scholar 

  29. Vashista M, Paul S (2012) Correlation between full width at half maximum (FWHM) of XRD peak with residual stress on ground surfaces. Philos Mag 92(33):4194–4204

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Apurbba Kumar Sharma.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Sharma, A.K., Venkatesh, G., Rajesha, S. et al. Experimental investigations into ultrasonic-assisted abrasive flow machining (UAAFM) process. Int J Adv Manuf Technol 80, 477–493 (2015). https://doi.org/10.1007/s00170-015-7009-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-015-7009-2

Keywords

Navigation