Article
Automation & Control Systems
Junye Li, Gongqiang Tian, Yanlu Yin, Guangfeng Shi, Jingran Zhang, Xinming Zhang
Summary: Higher standards have been set for the inner-surface finish of elbow-type parts in industrial production. This study analyzes the influence of inlet velocity, bend ratio, and bending angle on surface quality and establishes a surface quality control method for abrasive flow machining (AFM) elbows. The results show that raising the inlet velocity improves the machining effect, and the uniformity of overall machining is preferable for higher curvature radii. The numerical simulation and experimental findings agree and validate the accuracy and viability of AFM elbows.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Wulin Fan, Yuli Sun, Qinghuai Su, Jianshe Zhao, Fanxuan Yang
Summary: The study focused on the impact of wall-slip velocity of abrasive medium on the workpiece material removal rate in abrasive flow machining process. The coupling effect of wall shear stress and workpiece surface roughness on wall-slip characteristics was explored. A novel method based on fluid mechanics and AFM experiments was proposed to determine wall-slip velocity, and power-law mathematical models were derived to describe the relationship between wall-slip velocity, wall shear stress, and workpiece surface roughness. The models were validated through verification tests, and the results showed that the proposed method and mathematical models improved the prediction accuracy of MRR in AFM process.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Mechanical
S. M. Basha, M. R. Sankar, N. Venkaiah
Summary: Additive manufacturing of metallic parts often results in surface defects, which require post-processing. Abrasive flow finishing is commonly used, and in this study, it was found that using abrasive medium with bimodal particle distribution can improve the surface finish of selectively laser melted 18Ni300 steel.
Article
Automation & Control Systems
Linzhi Jiang, Tieyan Chang, Guixiang Zhang, Yu-Sheng Chen, Xue Liu, Haozhe Zhang
Summary: This study investigates the influence of different machining gaps on the surface integrity of zirconia ceramic (ZrO2) during magnetic abrasive finishing (MAF). It is found that both large and small machining gaps can lead to surface damage and compromise the integrity of ZrO2. The optimal machining gap is determined to be 2 mm, as it ensures significant grinding pressure while promoting plastic removal of the ceramic surface.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
S. M. Basha, N. Venkaiah, M. R. Sankar
Summary: Abrasive flow finishing (AFF) is an advanced surface finishing process that utilizes reciprocating abrasive media to gradually reduce the surface roughness of a component. Recently, hydrogel-based abrasive media have gained attention due to their cost-effectiveness, eco-friendliness, and biodegradability. However, the presence of water in these media may cause corrosion of component surfaces. In this study, a noncorroding and long-lasting abrasive medium was developed, which consists of galactomannan polymer, glycerol solution, cross-linker, and abrasive particles.
ADDITIVE MANUFACTURING
(2023)
Article
Engineering, Mechanical
Wulin Fan, Yuli Sun, Chao Liu, Jianshe Zhao, Fanxuan Yang
Summary: This study proposed a soft-contact model and defined soft-contact parameters to characterize soft-contact characteristics in abrasive flow machining (AFM). The study investigated the effect of medium pressure and particle diameter on soft-contact parameters, and found that the scratch depth of the abrasive particles increased with increasing particle diameter and medium pressure. The study also revealed that the abrasive particles were deeply wrapped by the abrasive medium and that the covering inclination angle increased with increasing medium pressure and particle diameter.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE
(2023)
Article
Engineering, Manufacturing
Subhadip Pradhan, Debabrata Dhupal
Summary: The study found that hot abrasive jet machining (hAJM) is a cost-effective method for machining aluminium nitride (AlN) ceramic materials. By using a hot abrasive stream, hAJM can cut AlN ceramics without causing thermal deformation. Computational fluid dynamics (CFD) modeling and experimental observation were used to analyze the material removal rate (MRR) and the effect of abrasive temperature, nozzle angle, and air pressure on the machined surface profile and material erosion. The results showed that hAJM can improve material removal efficiency and achieve better surface quality and erosion control.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Chemistry, Physical
Can Peng, Hang Gao, Xuanping Wang
Summary: This study introduces a comprehensive framework to address the challenges in abrasive flow machining, focusing on precise finishing and dimensional accuracy. By incorporating a novel compensation strategy and utilizing capillary flow, the study accurately characterizes the behavior of abrasive media, particularly at elevated shear rates, and demonstrates high accuracy and broad application potential.
Article
Engineering, Manufacturing
Nitin Dixit, Varun Sharma, Pradeep Kumar
Summary: The Ultrasonic-assisted magnetic abrasive flow machining (UAMAFM) process improves finishing performance by utilizing external ultrasonic and magnetic field assistance. Mathematical models were developed to analyze both steady-state and transient material removal and surface roughness. The predicted values from the mathematical models showed good agreement with experimental results.
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
(2022)
Review
Engineering, Manufacturing
Nitin Dixit, Varun Sharma, Pradeep Kumar
Summary: The review discusses the importance of abrasive flow machining in aerospace, automotive, and biomedical industries, as well as the systematic research methodology and various aspects of investigation into AFM.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Engineering, Manufacturing
Baocai Zhang, Yu Qiao, Nasim Khiabani, Xinchang Wang
Summary: The study analyzed the components, structures, and rheological behaviors of a typical media used in abrasive flow machining (AFM) process, as well as discussed the material removal mechanism and flow characteristics. By simulating and analyzing these behaviors, precise parameters of the media were determined to guide the design of micro structures machining procedures.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Automation & Control Systems
Qiuyan Wang, Moiz Sabbir Vohra, Shuowei Bai, Swee Hock Yeo
Summary: This study proposed a rotary ultrasonic-assisted abrasive flow finishing (RUA-AFF) method to improve the performance of the AFF process. Experimental results showed that higher ultrasonic vibration amplitude led to better surface quality and increased material removal rate (MRR); higher ultrasonic frequency and rotational speed slightly decreased surface roughness and MRR. There are two material removal modes in the RUA-AFF process, indicating efficient and high-quality finishing of Al6061.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Multidisciplinary
Shoya Mohseni-Mofidi, Lars Pastewka, Matthias Teschner, Claas Bierwisch
Summary: This study explores a numerical approach for soft abrasive flow machining (SAFM) to address fluid-structure interface issues and surface erosion, as well as to investigate the effect of an external magnetic field on machining performance. Results show that a magnetic field of suitable strength can considerably improve the performance of SAFM.
APPLIED MATHEMATICAL MODELLING
(2022)
Article
Chemistry, Analytical
Bo Du, Jinhu Wang, Julong Yuan, Binghai Lyu, Xinqian Zhang, Chunyu Zhang
Summary: A spherical-array-focused ultrasonic abrasive machining system was established to improve ultrasonic energy and achieve far-field ultrasonic abrasive machining of complex surfaces. The influences of ultrasonic generator current, abrasive concentration, and particle size on material removal properties and surface quality of quartz glass were investigated. The results showed that at low current levels, plastic removal at the nanoscale was observed, while higher current levels resulted in the formation of micron-scale impact removal traces. Increasing abrasive concentration increased impact density and material removal rate, but excessive concentration hindered removal. Abrasive particle size affected cavitation nucleation and acceleration, impacting material removal rate and surface quality.
Article
Engineering, Mechanical
Floriane Lavorel, Mohamed El Mansori, Faissal Chegdani, Abdel Tazibt
Summary: This study explores the feasibility of using a novel cutting process - cryogenic nitrogen jet, for machining biocomposites. Results show that the pressure and traverse speed of the nitrogen jet are key process parameters that determine the mechanical and thermal stresses experienced by the biocomposite during the machining operation.
Article
Engineering, Manufacturing
Palwinder Singh, Lakhvir Singh, Sehijpal Singh
JOURNAL OF MANUFACTURING PROCESSES
(2020)
Article
Engineering, Manufacturing
Palwinder Singh, Lakhvir Singh, Sehijpal Singh
Summary: This paper explores the use of magnetic field-assisted abrasive flow machining with bonded magnetic abrasives-based media to improve the surface quality of aluminum 6061 material tubes. Through optimization of parameters such as magnetic field strength, number of working cycles, and hydraulic pressure, the optimal processing conditions were determined to achieve maximum surface roughness improvement rate. Response surface methodology and model validation were used to verify the experimental results, leading to the identification of the best processing parameters.
MATERIALS AND MANUFACTURING PROCESSES
(2022)
Article
Engineering, Mechanical
Palwinder Singh, Lakhvir Singh
Summary: The study evaluated the effects of process parameters on surface finishing properties in Magnetically Assisted Abrasive Finishing (MAAF) and developed mathematical models for predicting desired surface finishing properties. Significant parameters such as magnetic field density (MFD) and speed were found to have a significant impact on surface roughness improvement rate and material removal rate, with abrasive grit size being the most dominant parameter. The models developed using Response Surface Methodology (RSM) had low error rates and could effectively predict the desired surface finishing properties.
SURFACE TOPOGRAPHY-METROLOGY AND PROPERTIES
(2021)
Article
Materials Science, Multidisciplinary
Amardeep Singh, Palwinder Singh, Sehijpal Singh, Lakhvir Singh
Summary: In the process of magnetic abrasive finishing (MAF), the selection of magnetic abrasives (MAs) and their preparation methods play a crucial role in achieving the desired surface finish of the workpiece. This study evaluates the effect of annealing temperature on the magnetic properties and finishing efficiency, and demonstrates that MAs annealed at different temperatures can improve both the magnetic properties and the surface finish of the workpiece.
JOURNAL OF MAGNETISM AND MAGNETIC MATERIALS
(2022)
Proceedings Paper
Materials Science, Multidisciplinary
Jagdeep Singh Gill, Lakhvir Singh, Palwinder Singh
Summary: In this study, a response surface methodology (RSM) optimization approach was applied to investigate the influence of process parameters on the rate of material removal in magnetic abrasive finishing. The results showed that the rate of material removal was affected by factors such as GAP, rotational speed, abrasive quantity, abrasive grit size, and machining time. The optimal combination of process parameters for maximum change in hardness was determined as GAP=3mm, rotational speed=500rpm, abrasive quantity=14g, abrasive grit size=128mm, and machining time=30min.
MATERIALS TODAY-PROCEEDINGS
(2022)
Proceedings Paper
Engineering, Mechanical
Palwinder Singh, Lakhvir Singh, Sehijpal Singh
Summary: Magnetic abrasive flow machining (MAFM) is a non-traditional machining technique that can provide excellent surface finish at a low cost. This study investigates the mechanism of material removal and roughness improvement in MAFM on non-magnetic, soft, and ductile workpieces through experimentation. The surfaces of the finished parts are also examined using SEM to understand the produced surface texture.
MACHINES, MECHANISM AND ROBOTICS, INACOMM 2019
(2022)
Article
Materials Science, Multidisciplinary
Palwinder Singh, Lakhvir Singh, Sehijpal Singh
INTERNATIONAL JOURNAL OF MATERIALS & PRODUCT TECHNOLOGY
(2020)