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Numerical and experimental investigation of abrasive flow machining of branching channels

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Abstract

Abrasive flow machining (AFM) is a key internal polishing technology applied to workpieces with difficult-to-reach areas. With the complex viscoelastic responses of abrasive media, the media flow is difficult to predict when the channel geometry is complex. It follows that the process outcome is also difficult to predict. In the present works, we proposed to use both experimental observations and computational fluid dynamics (CFD) simulations to investigate the responses of abrasive media in different branching channels during AFM process. We conducted measurement of media pressure and velocity during AFM for branching channels of different shapes and diameters. These data were used to develop and validate the present numerical model. The CFD simulations were conducted using the viscoelastic solver in OpenFOAM extension version, and we implemented log-conformation tensor representation (LCR) to stabilize the solver for high Weissenberg number problem (HWNP). The benchmark of the present simulations with experiments shows good agreement indicating that the present model is validated. The free-slip phenomenon of the abrasive media on the workpiece was uncovered from experimental observation of media flow in transparent channels and a sudden pressure drop (instead of a linear pressure drop) occurring across the connection between the workpiece and the fixture. Analysis of the numerical data indicates that the first normal stress difference (N1) plays an important role in the mass flow rate distributions of abrasive viscoelastic media in branching channels. Degradation of media properties was also studied and analyzed, suggesting that the flow pattern distribution in the workpieces could be influenced by media property degradation.

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Acknowledgments

The authors would like to thank Dr. Kang Chang Wei (Deputy Director, Fluid Dynamics Department, Institute of High Performance Computing, Singapore) for his contributions to support and resolve the issues that arose during the conduct of the research reported here. His experience in guiding and improving the manuscript is very beneficial. We also acknowledge the support of computational facilities from the National Supercomputer Centre (NSCC) in Singapore, without which the simulations undertaken in the present work would not have been possible.

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Authors and Affiliations

  1. Institute of High Performance Computing (IHPC), A*STAR, Singapore, Singapore

    Wu Chih-Hua & Wan Stephen Yee Ming

  2. Advanced Remanufacturing and Technology Centre (ARTC), A*STAR, Singapore, Singapore

    Kum Chun Wai & Abu Bakar Adri Muhammad

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  1. Wu Chih-Hua
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  2. Kum Chun Wai
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  3. Wan Stephen Yee Ming
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  4. Abu Bakar Adri Muhammad
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Correspondence to Wu Chih-Hua.

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Drawings of branching geometries

Drawings of branching geometries

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Chih-Hua, W., Chun Wai, K., Stephen Yee Ming, W. et al. Numerical and experimental investigation of abrasive flow machining of branching channels. Int J Adv Manuf Technol 108, 2945–2966 (2020). https://doi.org/10.1007/s00170-020-05589-z

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