Abrasive flow machining (AFM) technology is attracting more and more attention and keeps expanding into more areas by the industry and research community particularly in the context of increasing demands for post-processing of the complex aerofoil structures and additively manufactured components. It is fundamentally vital to develop an industrial feasible approach to controlling and improving the surface roughness of the structure and component, and even the profile accuracy and surface texture. In this paper, a multiscale multiphysics approach combining with micro-cutting mechanics is presented for modelling and analysis of the surface roughness and topography profile generation in the AFM process. The analysis is developed and implemented by using MATLAB programming integrated with the COMSOL multiphysics computational environment. Micro-cutting mechanics modelling and the Monte Carlo (MC) algorithms are integrated to develop simulations on the AFM generation of surface texture and topography through abrasive micro-machining with thousands of grains under complex multiscale and multiphysics working conditions. Well-designed AFM experiment trials on machining aerofoil structures are carried out to further evaluate and validate the modelling and analysis. The work presented is fundamental but essential as a part of the project for developing the simulation-based AFM virtual machining system.
Jain R, Jain V, Dixit P (1999) Modeling of material removal and surface roughness in abrasive flow machining process. Int J Mach Tool Manu 39:1903–1923, 1999
Howard M, Cheng K (2014) An integrated systematic investigation of the process variables on surface generation in abrasive flow machining of titanium alloy 6Al4V. Proc IMechE B J Eng Manuf 228(11):1419–1431
Cheng K, Shao Y, Bodenhorst R, Jadva M (2017) Modelling and simulation of material removal rates and profile accuracy control in abrasive flow machining of the IBR blade and experimental perspectives. Trans ASME J Manuf Sci Eng 139(12):121020
Kumar SS, Hiremath SS (2016) A review on abrasive flow machining (AFM). Procedia Technol 25:1297–1304
Rowe WB, Qi HS, Morgan MN, Zheng HW (1993) The real contact length in grinding based on depth of cut and contact deflections. In: Proceedings of the Thirtieth International MATADOR Conference. Palgrave, London, pp 187–193
Vogel L, Peukert W (2004) Determination of material properties relevant to grinding by practicable labscale milling tests. Int J Miner Process 74:S329–S338
Cheng K (ed) (2008) Machining dynamics: theory, applications and practices. Springer, London
Kruggel-Emden H, Simsek E, Rickelt S, Wirtz S, Scherer V (2007) Review and extension of normal force models for the discrete element method. Powder Technol 171(3):157–173
Davies PJ (1993) The rheological and honing characteristics of polyborosiloxane/grit mixtures (Doctoral dissertation, Sheffield Hallam University)
Jain R, Jain V (1999) Simulation of surface generated in abrasive flow machining process. Robot Comput Integr Manuf 15:403–412
Gorana VK, Jain VK, Lal GK (2006) Forces prediction during material deformation in abrasive flow machining. Wear 260(1-2):128–139
Barnes HA (2003) A review of the rheology of filled viscoelastic systems. Rheology Reviews (The British Society of Rheology, pp 1–36
Wan S, Ang YJ, Lim GC (2014) Process modelling and CFD simulation of two-way abrasive flow machining. Int J Adv Manuf Technol 71(5):1077–1086
Malkin S, Guo C (2008) Grinding technology: theory and application of machining with abrasives. Industrial Press Inc
Marinescu ID, Rowe WB, Dimitrov B, Inaski I (2004) Tribology of abrasive machining processes. Elsevier
Fang L, Cen Q, Sun K, Liu W, Zhang X, Huang Z (2005) FEM computation of groove ridge and Monte Carlo simulation in two-body abrasive wear. Wear 258(1-4):265–274
Mooney CZ (1997) Monte Carlo simulation, vol 116. Sage Publications
Weinan E (2011) Principles of multiscale modeling. Cambridge University Press
Howard M, Cheng K (2013) An industrially feasible approach to process optimization of abrasive flow machining and its implementation perspectives. Proc IMechE B J Eng Manuf 228(11):1419–1431
Desale GR, Gandhi BK, Jain SC (2011) Development of correlations for predicting the slurry erosion of ductile materials. J Tribol 133:031603. https://doi.org/10.1115/1.4004342
The authors are thankful for the regular meetings and discussions with industrial partners at the project consortium.
This study is financially supported by the National Aerospace Technology Exploitation Program (NATEP) (Project No. MAA073).
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
About this article
Cite this article
Shao, Y., Cheng, K. Integrated modelling and analysis of micro-cutting mechanics with the precision surface generation in abrasive flow machining. Int J Adv Manuf Technol 105, 4571–4583 (2019). https://doi.org/10.1007/s00170-019-03595-4
- Abrasive flow machining
- Multiscale modelling
- Monte Carlo algorithms
- Multiphysics simulation
- Surface roughness
- Aerofoil structures