Sage Journals: Discover world-class research

Abstract

This article presents a novel industrially feasible approach to ensure that an integrated optimum configuration of machine, media and geometry is achieved for abrasive flow machining process optimisation. Historically, new part introduction requires a trial-and-error phase to develop a process model, while the proposed method identifies two key explanatory variables (edge form and average roughness) and the process conditions in which they are achieved in testpiece geometry. The method and its shop-floor implementation perspectives are evaluated and verified through computational fluid dynamics simulation and well-designed machining trials, plus reapplied to more complex workpieces. The method can significantly improve abrasive flow machining process capability, accuracy and efficiency and be used to optimise machine design, attempt radical new methods of workpiece fixturing and provide an avenue to incorporate and reanalyse the adaptations of abrasive flow machining machinery.

Keywords

Abrasive flow machining flow deburring process optimisation computational fluid dynamics–based simulation

Get full access to this article

View all access options for this article.

References

Perry

. Abrasive flow machining method and tooling. Patent no. 4,005,549, USA, 1977.

Rhoades

. Medium for process of honing by extruding. Patent no. 3,819,343, USA, 1974.

Yang

Zhao

. The study of polishing and equipment of abrasive flow. In: Proceedings of 2010 international conference on mechanic automation and control engineering (MACE), Wuhan, China, 26–28 June 2010. IEEE, Beijing section CSS chapter, pp.3450–3453.

Arief

Chen

. Key parameters in loose abrasive machining. In: Proceedings of the computing and engineering researchers’ conference, Huddersfield, UK, 3 December 2010. University of Huddersfield, 2010.

Gorana

Jain

Lal

. Prediction of surface roughness during abrasive flow machining. Int J Adv Manuf Tech 2006; 31(3): 258–267.

Rhoades

. Abrasive flow machining: a case study. J Mater Process Tech 1991; 28(1): 107–116.

Mali

Manna

. Current status and application of abrasive flow finishing processes: a review. Proc IMechE, Part B: J Engineering Manufacture 2009; 223(7): 809–820.

Cheema

Venkatesh

Dvivedi

. Developments in abrasive flow machining: a review on experimental investigations using abrasive flow machining variants and media. Proc IMechE, Part B: J Engineering Manufacture 2012; 226(12): 1951–1962.

Wang

Tsai

Liang

. Uniform surface polished method of complex holes in abrasive flow machining. T Nonferr Metal Soc 2009; 19: 250–257.

An industrially feasible approach to process optimisation of abrasive flow machining and its implementation perspectives

Abstract

Keywords

Get full access to this article

References