Skip to main content
SpringerLink
Log in

Rotary ultrasonic-assisted abrasive flow finishing and its fundamental performance in Al6061 machining

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

Abstract

The geometric complexity of 3D-printed parts increases the difficulty of surface finishing with the conventional grinding technique. In this study, a rotary ultrasonic-assisted abrasive flow finishing (RUA-AFF) method is proposed towards improving the performance of the AFF process by providing rotary motion and ultrasonic vibration to the equipment. Finishing experiments are carried out involving Al6061 to investigate the capabilities of the proposed RUA-AFF. The obtained results show that (1) the higher ultrasonic vibration amplitude results in the greatest improvement in the work surface quality and a higher increase in material removal rate (MRR); (2) with the higher ultrasonic frequency and rotational speed, the surface roughness and MRR are decreased marginally; (3) there are two material remove modes in the RUA-AFF process: abrasive impingement and micro-cutting. These indicate that the high efficiency and high-quality finishing of Al6061 can be performed with the proposed RUA-AFF technique.

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

Similar content being viewed by others

References

  1. Sankar MR, Jain VK, Ramkumar J (2020) Rotational abrasive flow finishing (R-AFF) process and its effects on finished surface topography. Int J Mach Tool Manu 50:637–650

    Article  Google Scholar 

  2. Rhoades LJ, Kohut TA, Nokovich NP, Yanda DW (1994) Unidirectional abrasive flow machining. US patent number 5(367):833

    Google Scholar 

  3. Rhoades LJ, Kohut TA (1991) Reversible unidirectional AFM. US patent number 5(070):652

    Google Scholar 

  4. Sankar MR, Ramkumar J, Jain VK (2008) Abrasive flow machining (AFM): an overview. INDO-US WORKSHOP on smart machine tools, intelligent machining systems and multi-scale manufacturing, In

    Google Scholar 

  5. Singh S, Shan HS (2002) Development of magneto abrasive flow machining process. Int J Mach Tool Manu 42:953–959

    Article  Google Scholar 

  6. Jha S, Jain VK (2004) Design and development of the magnetorheological abrasive flow finishing (MRAFF) process. Int J Mach Tool Manu 44:1019–1029

    Article  Google Scholar 

  7. Walia RS, Shan HS, Kumar PK (2009) Enhancing AFM process productivity through improved fixturing. Int J Adv Manuf Technol 44:700–709

    Article  Google Scholar 

  8. Kumar S, Jain VK, Sidpara A (2015) Nanofinishing of freeform surfaces (knee joint implant) by rotational-magnetorheological abrasive flow finishing (R-MRAFF) process. Precis Eng 42:165–178

    Article  Google Scholar 

  9. Sharma A K, Kumar P, Rajesh S (2011) An improved ultrasonic abrasive flow machining. Patent Number 3578/DEL/201, Indian.

  10. Venkatesh G, Sharma AK, Kumar P (2015) On ultrasonic assisted abrasive flow finishing of bevel gears. Int J Mach Tool Manu 89:29–38

    Article  Google Scholar 

  11. Hashimoto F, Yamaguchi H, Krajnik P, Wegener K, Chaudhari R, Hoffmeister H, Kuster F (2016) Manufacturing technology abrasive fine-finishing technology. CIRP Ann - Manuf Technol 65:597–620

    Article  Google Scholar 

  12. Mirjavadi S S, Afshari B M, Shafiei N, Rabby S, Kazemi M (2017) Effect of temperature and porosity on the vibration behavior of two-dimensional functionally graded micro-scale Timoshenko beam. Journal of Vibration and Control 1–15.

  13. Azimi M, Mirjavadi SS, Shafiei N, Hamouda AMS (2017) Thermo-mechanical vibration of rotating axially functionally graded nonlocal Timoshenko beam. Appl Phys A Mater Sci Process 104:1–15

    Google Scholar 

  14. Mirjavadi SS, Afshari BM, Khezel M, Shafiei N, Rabby S, Kordnejad M (2018) Nonlinear vibration and buckling of functionally graded porous nanoscaled beams. J Braz Soc Mech Sci Eng 352:1–12

    Google Scholar 

  15. Mirjavadi S S, Forsat M, Barati M R, Hamouda A M (2020) Nonlinear vibrations of variable thickness curved panels made of multi-scale epoxy/fiberglass/CNT material using Jacobi elliptic functions. Mechanics Based Design of Structures and Machines 1-17.

  16. Wu QN, Chen HH, Gao W (2019) Nonlocal strain gradient forced vibrations of FG-GPLRC nanocomposite microbeams. Eng Comput 36:1739–1750

    Article  Google Scholar 

  17. Forsat M (2019) Investigating nonlinear vibrations of higher-order hyper-elastic beams using the Hamiltonian method. Acta Mech 231:125–138

    Article  MathSciNet  Google Scholar 

  18. Tawakoli T, Azarhoushang B (2009) Ultrasonic assisted dry grinding of 42CrMo4. Int J Adv Manuf Technol 42:883–891

    Article  Google Scholar 

  19. Venkatesh G, Sharma AK, Singh N (2015) Simulation of media behaviour in vibration assisted abrasive flow machining. Simul Model Pract Theory 51:1–13

    Article  Google Scholar 

  20. Venkatesh G, Sood D, Sharma AK (2018) On surface integrity of Al 2014 alloy finished by ultrasonic assisted abrasive flow machining. Mater Sci Eng 346:012057

    Google Scholar 

  21. Lee YH, W K L, Jhou JH (2013) Two-dimensional vibration-assisted magnetic abrasive finishing of stainless steel SUS304. Int J Adv Manuf Technol 69:2723–2733

    Article  Google Scholar 

  22. Sharma AK, Venkatesh G, Rajesha S, Kumar P (2015) Experimental investigations into ultrasonic-assisted abrasive flow machining (UAAFM) process. Int J Adv Manuf Technol 80:477–493

    Article  Google Scholar 

  23. Ning FD, Wang H, Cong WL, Femando PKSC (2017) A mechanistic ultrasonic vibration amplitude model during rotary ultrasonic machining of CFRP composites. Ultrasonics 76:44–51

    Article  Google Scholar 

  24. Ulhmann E, Spur G, Holl S (1999) Machining of complex contours by ultrasonic assisted grinding. SME Technical Paper-MR99-284, 3rd International Machining and Grinding Conference, Cincinnati, Ohio, Oct.

  25. Kanel GI, Zaretsky EB, Rajendran AM, Razorenov SV, Savinykh AS, Paris V (2009) Search for conditions of compressive fracture of hard brittle ceramics at impact loading. Int J Plast 25:649–670

    Article  Google Scholar 

  26. Cao JG, Wu YB, Lu D, Fujimoto M, Nomura M (2014) Material removal behavior in ultrasonic-assisted scratching of SiC ceramics with a single diamond tool. Int J Mach Tool Manu 79:49–61

    Article  Google Scholar 

Download references

Funding

This project is supported by the National Natural Science Foundation of China (No.51705269, 71701109).

Author information

Authors and Affiliations

  1. School of Electromechanic Engineering, Qingdao University, Qingdao, 266071, People’s Republic of China

    Qiuyan Wang & Shuowei Bai

  2. School of Mechanical and Aerospace Engineering, Nanyang Technological University, Singapore, 639798, Singapore

    Moiz Sabbir Vohra & Swee Hock Yeo

Authors
  1. Qiuyan Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Moiz Sabbir Vohra
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Shuowei Bai
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Swee Hock Yeo
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

We would like to declare the contributions made by the following authors:

1) Qiuyan Wang—Development of the operation principle and kinematic characteristics of RUA-AFF and manuscript preparation

2) Moiz Sabbir Vohra—Design of experiments, data collections, and compilation

3) Shuowei Bai—kinematic analyses and result analyses

4) Swee Hock Yeo—outline of manuscript, review, and editing of the manuscript

Corresponding author

Correspondence to Swee Hock Yeo.

Ethics declarations

Ethics approval and consent to participate

This is to confirm all four authors have agreed to participate and have contributed to the content of the paper.

Consent for publication

All the authors herein have consented to the publication of the paper.

Competing interest

The authors declare no competing interest.

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

Wang, Q., Vohra, M.S., Bai, S. et al. Rotary ultrasonic-assisted abrasive flow finishing and its fundamental performance in Al6061 machining. Int J Adv Manuf Technol 113, 473–481 (2021). https://doi.org/10.1007/s00170-021-06666-7

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-06666-7

Keywords

Search

Navigation