Abstract
The conventional abrasive flow machining (AFM) and its derivatives (i.e., magneto, electro-chemical, and ultrasonic-aided AFMs) demand special machining devices, which limits the application and dissemination of AFM. A new AFM is developed in this study, which demands no extra special devices except for a tool bar made with cemented carbide. The effect of dynamic viscosity of abrasive medium, standoff distance, and tool bar rotating speed on pressure and velocity distributions of flow field is investigated using a numerical model. Moreover, experiments are conducted to explore the influence of abrasive-laden medium and process key parameters on this new AFM finishing effect. The results indicate that the pressure and velocity of flow field reach their maximum at the middle of the minimum standoff distance between tool bar and workpiece. The optimum abrasive grain size utilized in this AFM is found to be related to the minimum standoff distance between tool bar and workpiece during finishing process. The obtained optimum tool bar rotating speed, traverse speed, and number of processing cycles are 19,200 r/min, 500 mm/min, and 500 cycles, respectively. This new AFM is anticipated to become an efficient and economic tool for surface finishing.
Similar content being viewed by others
References
Singh S, Kumar D, Sankar MR, Rajurkar KP (2018) Nano-finishing of micro-slots on surgical stainless steel by abrasive flow finishing process: experimentation and modeling. J Micro Nano-Manuf 6(2):1–12. https://doi.org/10.1115/1.4039295
Hiremath SS, Vidyadhar HM, Singaperumal M (2015) A novel approach for finishing internal complex features using developed abrasive flow finishing machine. Int J Recent Adv Mech Eng 2(4):37–44
Kumar SS, Hiremath SS (2016) A review on abrasive flow machining (AFM). Procedia Technol 25:1297–1304. https://doi.org/10.1016/j.protcy.2016.08.224
Jain VK, Adsul SG (1999) Experimental investigations into abrasive flow machining (AFM). Int J Mach Tools Manuf 40(7):1003–1021. https://doi.org/10.1016/S0890-6955(99)00114-5
Lv Z, Hou R, Tian Y, Huang C, Zhu H (2018) Investigation on flow field of ultrasonic-assisted abrasive waterjet using CFD with discrete phase model. Int J Adv Manuf Technol 96(1–4):963–972. https://doi.org/10.1007/s00170-018-1635-4
Mirjavadi SS, Alipour M, Hamouda AMS, Matin A, Kord S, Afshari BM, Koppad PG (2017) Effect of multi-pass friction stir processing on the microstructure, mechanical and wear properties of AA5083/ZrO2 nanocomposites. J Alloy Compd 726:1262–1273. https://doi.org/10.1016/j.jallcom.2017.08.084
Mirjavadi SS, Alipour M, Emamian S, Kord S, Hamouda AMS, Koppad PG, Keshavamurthy R (2017) Influence of TiO2 nanoparticles incorporation to friction stir welded 5083 aluminum alloy on the microstructure, mechanical properties and wear resistance. J Alloy Compd 712:795–803. https://doi.org/10.1016/j.jallcom.2017.04.114
Singh S, Shan HS (2002) Development of magneto abrasive flow machining process. Int J Mach Tools Manuf 42(8):953–959. https://doi.org/10.1016/S0890-6955(02)00021-4
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. https://doi.org/10.1080/10910340600902157
Dabrowski L, Marciniak M, Szewczyk T (2006) Analysis of abrasive flow machining with an electrochemical process aid. Proc Inst Mech Eng Part B-J Eng Manuf 220(3):397–403. https://doi.org/10.1243/095440506X77571
Sharma AK, Venkatesh G, Rajesha S, Kumar P (2015) Experimental investigations into ultrasonic-assisted abrasive flow machining (UAAFM) process. Int J Adv Manuf Technol 80(1–4):477–493. https://doi.org/10.1007/s00170-015-7009-2
Das M, Jain VK, Ghoshdastidar PS (2011) Nano-finishing of flat workpieces using rotational magnetorheological abrasive flow finishing (R-MRAFF) process. Int J Adv Manuf Technol 62(1–4):405–420. https://doi.org/10.1007/s00170-011-3808-2
Kowsari K, Nouhi A, Hadavi V (2017) Prediction of the erosive footprint in the abrasive jet micro-machining of flat and curved glass. Tribol Int 106:101–108. https://doi.org/10.1016/j.triboint.2016.10.038
Nouraei H, Kowsari K, Samareh B (2016) Calibrated CFD erosion modeling of abrasive slurry jet micro-machining of channels in ductile materials. J Manuf Process 23:90–106. https://doi.org/10.1016/j.jmapro.2016.06.007
Kumar A, Kumar V, Kumar J (2013) Investigation of machining parameters and surface integrity in wire electric discharge machining of pure titanium. Proc Inst Mech Eng Part B-J Eng Manuf 227(7):972–992. https://doi.org/10.1177/0954405413479791
Sushil M, Vinod K, Harmesh K (2018) Multi-objective optimization of process parameters involved in micro-finishing of AI/SiC MMCs by abrasive flow machining process. Proc Inst Mech Eng Pt L-J Mater-Design Appl 232(4):319–332. https://doi.org/10.1177/1464420715627292
Wang TT (2013) Fundamental research on the abrasive flow finishing machining. Dissertation, Nanjing University of Aeronautics and Astronautics
Zhou X (2016) Study on the mechanism of abrasive flow finishing machining based on the hydrodynamic effects. Dissertation, Nanjing University of Aeronautics and Astronautics
Dash R, Maity K (2015) Simulation of abrasive flow machining process for 2D and 3D mixture models. Front Mech Eng 10(4):424–432. https://doi.org/10.1007/s11465-015-0366-6
Sun S F (2013) Research of abrasive flow turbulence regulation and machining mechanism for mold structural surface finishing Dissertation, Zhejiang University of Technology
Langhi M, Hosoda T, Dey S (2018) Analytical solution of k-epsilon model for nonuniform flows. J Hydraul Eng-ASCE 144(7):67–72. https://doi.org/10.1061/(ASCE)HY.1943-7900.0001472
Amudhavel J, Reddy LS, Raghav RS (2018) A detailed analysis of computational fluid dynamics methods and its engineering applications. Biosci Biotechnol Res Commun 1(SI):29–33
Chen D, Ling C, Wang TT, Su Q, Ye AJ (2018) Prediction of tire-pavement noise of porous asphalt mixture based on mixture surface texture level and distributions. Constr Build Mater 173:801–810. https://doi.org/10.1016/j.conbuildmat.2018.04.062
Chen D (2018) Evaluating asphalt pavement surface texture using 3D digital imaging. Int J Pavement Eng 1(1):1–12. https://doi.org/10.1080/10298436.2018.1483503
Chen D, Han S, Ling C, Su Q (2017) Prediction of asphalt mixture surface texture level and its distributions using mixture design parameters. Int J Pavement Eng 1(1):1–24. https://doi.org/10.1080/10298436.2017.1316644
GB/T 1031–2009 (2009) Geometrical product specifications (GPS)-surface texture: profile method—surface roughness parameters and their values. General administration of quality supervision, inspection and quarantine of the People’s Republic of China
Acknowledgements
The Research Fund of the National Natural Science Foundation of China [Grant No. 51808462], the Research Fund of “State Key Laboratory of Rail Transit Engineering Informatization (FSDI) [Grant No. SKLK2018-09]”, the Research Fund of the “Cracking Resistance Technology of RCC Base Used in Heavy Traffic City Expressway in Hot and Rainy Areas” [Grant No. 2018 K111], the Research Fund of “State-Key Laboratory of Traction Power” [Grant No.2018 TPL_T01], and the Fundamental Research Funds for the Central Universities [Grant No. 2682016CX009] are gratefully acknowledged. The authors also would like to acknowledge the contribution to Mr. Zhou, Xin from Nanjing University of Aeronautics and Astronautics.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Wang, T., Chen, D., Zhang, W. et al. Study on key parameters of a new abrasive flow machining (AFM) process for surface finishing. Int J Adv Manuf Technol 101, 39–54 (2019). https://doi.org/10.1007/s00170-018-2914-9
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-2914-9