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Viscoelastic medium modeling and surface roughness simulation of microholes finished by abrasive flow finishing process

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Abstract

Surface roughness is one of the critical parameters that affect the component performance during its working life. To develop any process to its full potential, it is necessary to understand the physics of that process. Abrasive flow finishing (AFF) is one of the advanced finishing processes. In the current research work, an effort is made to understand physics and mechanism of surface roughness improvement during the AFF process. This research paper is divided into two sections. Firstly, the amount of finishing stresses and forces generated during the finishing of microholes fabricated on surgical stainless steel (316L) workpieces are computed by using the finite element method. Finishing stresses are generated in the viscoelastic medium. So, to compute finishing stresses, finite element analysis of the viscoelastic medium is carried out by incorporating its experimentally measured rheological properties. Finishing stresses are calculated along the circumferential direction of the microhole. Later, at the same workpiece surface location, simulated and experimentally measured surface roughness value are compared. Secondly, a new simulation model is proposed to predict the surface roughness on the microhole wall surface for various AFF input parameters. Maximum percentage change in surface roughness error of 8% is observed between simulated and experimental results after AFF process.

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Acknowledgements

The authors are thankful for the financial support provided by Board of Research in Nuclear Sciences (Project Number ME/P/MRS/02), Department of Science and Technology for their Technology Systems Development Program (DST/TSG/AMT/2015/619), and Defense Research Development & Development Laboratory (CARS Project).

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Authors and Affiliations

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

    Sachin Singh, Deepu Kumar & M. Ravi Sankar

  2. Department of Mechanical Engineering, Indian Institute of Technology Kanpur, Kanpur, 208016, India

    V. K. Jain

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  1. Sachin Singh
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  2. Deepu Kumar
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  3. M. Ravi Sankar
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  4. V. K. Jain
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Correspondence to M. Ravi Sankar.

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Singh, S., Kumar, D., Ravi Sankar, M. et al. Viscoelastic medium modeling and surface roughness simulation of microholes finished by abrasive flow finishing process. Int J Adv Manuf Technol 100, 1165–1182 (2019). https://doi.org/10.1007/s00170-018-1912-2

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  • DOI: https://doi.org/10.1007/s00170-018-1912-2

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