Finishing force analysis and simulation of nanosurface roughness in abrasive flow finishing process using medium rheological properties

Surface roughness plays a vital role in functional requirements of a component. Abrasive flow finishing (AFF) is an advanced finishing process used to achieve micro/nanolevel surface finish in complex geometries, internal inaccessible pathways made up of difficult to finish material, etc. In order to control the process and improve its performance, it is important to understand the mechanism of finishing. In this paper, an attempt has been made to model the forces generated during AFF process using the rheological properties of the viscoelastic medium used in the process. Secondly, by using the calculated forces, simulation of the final surface roughness profile of the workpiece has been presented. The simulated results are in good agreement with the experimental results.

[2]  Vijay K. Jain,et al.  Advanced Machining Processes , 2014 .

[3]  V. Jain,et al.  Rheological Properties and Their Correlation with Surface Finish Quality in MR Fluid-Based Finishing Process , 2014 .

[4]  K. Kar,et al.  Preferential Media for Abrasive Flow Machining , 2009 .

[5]  P J Davies,et al.  The Assessment of the Rheological Characteristics of Various Polyborosiloxane/Grit Mixtures as Utilized in the Abrasive Flow Machining Process , 1995 .

[6]  Vijay K. Jain,et al.  Analysis of magnetorheological abrasive flow finishing (MRAFF) process , 2008 .

[7]  Christopher W. Macosko,et al.  Rheology: Principles, Measurements, and Applications , 1994 .

[8]  M. S. Shunmugam,et al.  MAGNETIC FIELD ANALYSIS AND ROUGHNESS PREDICTION IN MAGNETORHEOLOGICAL ABRASIVE HONING (MRAH) , 2009 .

[9]  G. K. Lal,et al.  Forces prediction during material deformation in abrasive flow machining , 2006 .

[10]  Vijay K. Jain,et al.  Simulation of surface generated in abrasive flow machining process , 1999 .

[11]  Stephen Wan,et al.  Process modeling and CFD simulation of two-way abrasive flow machining , 2014 .

[12]  Vijay K. Jain,et al.  Modeling of material removal and surface roughness in abrasive flow machining process , 1999 .

[13]  V. Jain,et al.  Fluid flow analysis of magnetorheological abrasive flow finishing (MRAFF) process , 2008 .

[14]  V. Jain,et al.  A 2D CFD simulation of MR polishing medium in magnetic field-assisted finishing process using electromagnet , 2015 .

[15]  Kamlakar P Rajurkar,et al.  A study of the effects of abrasive-flow finishing on various machined surfaces , 1994 .

[16]  Kuan-Yu Chen,et al.  A study of helical passageways applied to polygon holes in abrasive flow machining , 2014 .

[17]  K. Kar,et al.  Performance evaluation and rheological characterization of newly developed butyl rubber based media for abrasive flow machining process , 2009 .

[18]  Pradeep Kumar,et al.  Some aspects of centrifugal force assisted abrasive flow machining of 2014 Al alloy , 2008 .

[19]  Larry Rhoades,et al.  Abrasive flow machining: a case study , 1991 .

[20]  V. K. Jain,et al.  Rheological characterization of styrene-butadiene based medium and its finishing performance using rotational abrasive flow finishing process , 2011 .

[21]  J. B. Hull,et al.  Rheology of Carrier Media Used in Abrasive Flow Machining , 1992 .

[22]  Rajendra K. Jain,et al.  Finite element simulation of abrasive flow machining , 2003 .

[23]  V. Jain,et al.  Stochastic simulation of active grain density in abrasive flow machining , 2004 .

[24]  A. C. Wang,et al.  Study of the rheological properties and the finishing behavior of abrasive gels in abrasive flow machining , 2007 .

[25]  V. K. Jain,et al.  EVALUATION OF RHEOLOGICAL PROPERTIES OF MEDIUM FOR AFM PROCESS , 2001 .

[26]  V. K. Jain,et al.  Experimental investigation and mechanism of material removal in nano finishing of MMCs using abrasive flow finishing (AFF) process , 2009 .

[27]  G. K. Lal,et al.  Prediction of surface roughness during abrasive flow machining , 2006 .

[28]  G. K. Lal,et al.  Experimental investigation into cutting forces and active grain density during abrasive flow machining , 2004 .

[29]  H S Shan,et al.  Finite element analysis of media used in the centrifugal force assisted abrasive flow machining process , 2006 .

[30]  V. Jain,et al.  Rheological Characterization of Magnetorheological Finishing Fluid , 2009 .