Skip to main content
SpringerLink
Log in

Cutting factors and testing of highly viscoelastic fluid abrasive flow machining

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

Abstract

This study used fluid abrasive as a two-phase flow to investigate the composition and function of the cutting force of abrasive flow machining (AFM). The slipping cutting factor Kf describing the finishing ability of the viscoelastic fluid abrasive and the cutting factor KT of the abrasive phase are defined for the cutting force of AFM. The theoretical equation for calculating the cutting factors is given, and the test method of the variable sliding friction coefficient for cutting factors is proposed and tested in this study. The results show that the finishing force of AFM is proportional to the pressure of the flow field on the surface of a workpiece. The abrasive phase cutting factors are related to the abrasive particle size, mass mixing ratio, and surface characteristics of the workpiece, and not to the viscosity of the carrier. Further, the finishing force of the fluid abrasive can be enhanced by increasing the softener content.

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

Access this article

Log in via an institution

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

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11

Similar content being viewed by others

Data availability

All data generated or analyzed during this study are included in this published article. The datasets used for this study are publicly available and anonymous.

Abbreviations

ds :

Microbody

P w :

Normal pressure of microbody (N)

σ w :

Shear stress of microbody (N)

dF T :

Finishing cutting force of microbody (N)

dF ’ T :

Reaction force of dFT (N)

Re:

Reynolds number

ΔU :

Flow rate difference (mm/s)

∇P :

Pressure gradient (MPa)

ψ m :

Mass mixing ratio

d p :

Particle size of abrasive particles (μm)

ø :

Shape coefficient

H w :

Surface hardness (N/mm2)

Ra w :

Surface roughness (μm)

G 0 :

Weight of workpiece (N)

G top :

Weight of upper force sensor (N)

N D0 :

Reading difference (N)

F M1 :

Total force (N)

F T1 :

Total cutting force (N)

K f :

Sliding cutting factor of fluid abrasives

F sl :

Sliding force of abrasive particles (N)

F pl :

Plowing force of abrasive particles (N)

F ch :

Cutting force of abrasive particles (N)

μw :

Coefficient of friction

F f,sl :

Sliding force of abrasive particles per unit area (N)

F N :

Normal force of abrasive particles (N)

F t,pl :

Plowing force of abrasive particles per unit area (N)

F f,pl :

Friction force of abrasive particles per unit area (N)

k pl :

Plow coefficient

K re :

Tangential cutting coefficient

h :

Thickness of the undeformed chips (μm)

dz :

Cutting depth (μm)

k t :

Cutting coefficient of the single abrasive particle

F t,ch :

Cutting force of abrasive particles (N)

K dRa :

Coefficient

l :

Cutting distance of abrasive particles (mm)

W v :

Cutting volume of abrasive particles (mm3)

A s :

Projection area of the abrasive particle cutting part (mm2)

N f :

Number of abrasive particles involved in sliding

N pl :

Number of abrasive particles involved in plowing

N t :

Number of abrasive particles involved in microcutting

N s :

Total number of abrasive particles

ds p :

Contact area between abrasive particles and workpiece (mm2)

ds c :

Contact area between the carrier and the workpiece (mm2)

K T :

Cutting factor of abrasive particle phase

μc :

Coefficient of sliding friction

μ c1 :

Friction coefficients of carrier VLFA-I and workpiece

μ c2 :

Friction coefficients of carrier VLFA-II and workpiece

References

  1. Gao H, Wu MY, Fu YZ, Guo DM (2015) Development of theory and technology of fluid abrasive finishing. J Mech Eng 51(7):174–187. https://doi.org/10.3901/JME.2015.07.174

    Article  Google Scholar 

  2. Munhoz MR, Dias LG, Breganon R, Ribeiro FSF, Gonçalves JFDS, Hashimoto EM, Júnior CEDS (2020) Analysis of the surface roughness obtained by the abrasive flow machining process using an abrasive paste with oiticica oil. Int J Adv Manuf Technol 106:5061–5070. https://doi.org/10.1007/s00170-019-04920-7

    Article  Google Scholar 

  3. Gorana VK, Jain VK, Lal GK (2006) Forces prediction during material deformation in abrasive flow machining. Wear 260(1-2):128–139. https://doi.org/10.1016/j.wear.2004.12.038

    Article  Google Scholar 

  4. Dong ZG, Ya G, Song GZ, Li YZ (2010) Analysis of the influence of abrasive viscoelasticity on grinding effect in abrasive flow machining. Diam Abras Eng 30(6):82–85. https://doi.org/10.3969/j.issn.1006-852X.2010.06.019

    Article  Google Scholar 

  5. Dong ZG, Ya G, Li YZ (2013) Material removal rate model of abrasive finishing with high viscoelastic fluid. Acta Armamentarii 34(12):1555–1561. https://doi.org/10.3969/j.issn.1000-1093.2013.12.010

    Article  Google Scholar 

  6. Ding JF, Liu RZ, Zhang KH, SJ E (2014) Micro-cutting mechanism of abrasive flow finishing. Opt Precis Eng 22(12):3324–3331. https://doi.org/10.3788/OPE.20142212.3324

    Article  Google Scholar 

  7. Zhang KH, Min L, Ding JF, Xu YC, Cheng GM (2014) Micro-cutting of driving force and controllable influencing factors in abrasive flow machining. China Mech Eng 25(18):2432–2438. https://doi.org/10.3969/j.issn.1004-132X.2014.18.004

    Article  Google Scholar 

  8. Jain RK, Jain VK (2001) Specific energy and temperature determination in abrasive flow machining process. Int J Mach Tools Manuf 44(12):1689–1704. https://doi.org/10.1016/S0890-6955(01)00043-8

    Article  Google Scholar 

  9. Jain RK, Jain VK (2000) Optimum selection of machining conditions in abrasive flow machining using neural network. J Mater Process Technol 108(1):62–67. https://doi.org/10.1016/S0924-0136(00)00621-X

    Article  Google Scholar 

  10. Gorana VK, Jain VK, Lal GK (2004) Experimental investigation into cutting forces and active grain density during abrasive flow machining. Int J Mach Tools Manuf 44(2-3):201–211. https://doi.org/10.1016/j.ijmachtools.2003.10.004

    Article  Google Scholar 

  11. Bähre D, Brünnet H, Swat M (2012) Investigation of one-way abrasive flow machining and in-process measurement of axial forces. Procedia CIRP 1:419–424. https://doi.org/10.1016/j.procir.2012.04.075

    Article  Google Scholar 

  12. Dong ZG, Ya G, Liu JC (2017) Study on machining mechanism of high viscoelastic abrasive flow machining for surface finishing. Proc Inst Mech Eng B J Eng Manuf 231(4):608–617. https://doi.org/10.1177/0954405415586967

    Article  Google Scholar 

  13. Wei HB, Peng C, Gao H, Wang XP, Wang XY (2019) On establishment and validation of a new predictive model for material removal in abrasive flow machining. Int J Mach Tools Manuf 138:66–79. https://doi.org/10.1016/j.ijmachtools.2018.12.003

    Article  Google Scholar 

  14. Bouland C, Urlea V, Beaubier K (2019) Abrasive flow machining of laser powder bed-fused parts: numerical modeling and experimental validation. J Mater Process Technol 273:1–13. https://doi.org/10.1016/j.jmatprotec.2019.116262

    Article  Google Scholar 

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

    Article  Google Scholar 

  16. Abebe M, Appl FC (1988) Theoretical analysis of the basic mechanics of abrasive processes: part I: general model. Wear 126(3):251–266. https://doi.org/10.1016/0043-1648(88)90169-X

    Article  Google Scholar 

  17. Vijayaraghavan R, Garg A, Vijayaraghavan V, Gao L (2015) Development of energy consumption model of abrasive machining process by a combined evolutionary computing approach. Meas 75:171–179. https://doi.org/10.1016/j.measurement.2015.07.055

    Article  Google Scholar 

  18. Vathaire MD, Delamare F, Felder E (1981) An upper bound model of ploughing by a pyramidal indenter. Wear 66(1):55–64. https://doi.org/10.1016/0043-1648(81)90032-6

    Article  Google Scholar 

  19. Malekian M, Park SS, Jun MBG (2009) Modeling of dynamic micro-milling cutting forces. Int J Mach Tools Manuf 49(7-8):586–598. https://doi.org/10.1016/j.ijmachtools.2009.02.006

    Article  Google Scholar 

  20. De Pater AD, Kalker JJ, Goodman LE (1976) The mechanics of the contact between deformable bodies. J Appl Mech 43(4):701–702. https://doi.org/10.1115/1.3423968

    Article  Google Scholar 

Download references

Funding

This work is supported by the Natural Science Basic Plan in Shanxi Province of China (201701D121074).

Author information

Authors and Affiliations

  1. College of Mechanical and Vehicle Engineering, Taiyuan University of Technology, Taiyuan, 030024, China

    Zhiguo Dong, Yuchao Zhang & Hongbo Lei

  2. Shanxi Key Laboratory of Precision Machining, Taiyuan, 030024, China

    Zhiguo Dong, Yuchao Zhang & Hongbo Lei

Authors
  1. Zhiguo Dong
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Yuchao Zhang
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Hongbo Lei
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Zhiguo Dong contributed to the derivation of theory and design of experiments and was a major contributor in writing the manuscript. Yuchao Zhang contributed to the analysis of data and operation of experiments. Hongbo Lei contributed to the operation of equipment and collection of data. All authors read and approved the final manuscript.

Corresponding author

Correspondence to Zhiguo Dong.

Ethics declarations

Competing interests

The authors declare that they have no competing interests.

Ethical approval

This study complies with the ethical standards set out by Springer.

Consent to participate

Not applicable.

Consent to publish

Not applicable.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Dong, Z., Zhang, Y. & Lei, H. Cutting factors and testing of highly viscoelastic fluid abrasive flow machining. Int J Adv Manuf Technol 112, 3459–3470 (2021). https://doi.org/10.1007/s00170-021-06619-0

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-06619-0

Keywords

Search

Navigation