Effect of Media Degradation on Finishing Characteristics in Abrasive Flow Machining

Abstract:

Abrasive flow machining (AFM) is one of the most promising technologies for internal finishing and de-burring for features with complex geometry. This study investigates the effect of media degradation on finishing characteristics achieved using the AFM process. A total of 50 experiments, using Inconel 718 cylindrical coupons machined by Wire-Electron Discharge Machining (WEDM), were conducted employing the same process conditions while using a single batch of AFM media. Experimental results indicate that media degradation has minor influence on surface roughness, but more significant influence on material removal and media flow rate. Material removal decreases exponentially with increasing cumulative media flow volume despite media flow rate increasing. There is a linear correlation between material removal and media flow rate. As a result, material removal can be estimated from media flow rate which can be monitored easily.

• Periodical: Materials Science Forum (Volume 874)
• Pages: 127-132
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.874.127
• Online since: October 2016
• Authors: Takashi Sato, Edwin Soh, Yuuichiro Nakayama, Miki Shinagawa, Yasuhiko Fukuchi
• Keywords: Abrasive Flow Machining, EDM Surface, Inconel Alloy, Internal Surface, Material Removal, Media Life

References

[1] V.K. Gorana, V.K. Jain, G.K. Lal: Experimental investigation into cutting forces and active grain density during abrasive flow machining, International Journal of Machine Tools & Manufacture 44 (2004), 201-211.

DOI: 10.1016/j.ijmachtools.2003.10.004

[2] Satish Kumar, V.K. Jain and Ajay Sidpara, Nanofinishing of freeform surface (knee joint implant) by rotational-magnetorheological abrasive flow finishing (R-MRAFF) process, Precision Engineering (2015), in press.

DOI: 10.1016/j.precisioneng.2015.04.014

[3] G. Venkatesh, Apurbba, Kumar Sharma and Pradeep Kumar, On ultrasonic assisted abrasive flow finishing of bevel gears, International Journal of Machine Tools & Manufacturing 89 (2015) 29-38.

DOI: 10.1016/j.ijmachtools.2014.10.014

[4] V. K. Jain , S.G. Adsul: Experimental investigations into abrasive flow machining (AFM), International Journal of Machine Tools & Manufacture 40 (2000), p.1003.

DOI: 10.1016/s0890-6955(99)00114-5

[5] V. K. Gorana . V. K. Jain . G. K. Lal: Prediction of surface roughness during abrasive flow machining, International Journal of Advanced Manufacturing Technology 31 (2006), 258-267.

DOI: 10.1007/s00170-005-0197-4

[6] V.K. Jain, Rajani Kumar, P.M. Dixit, Ajay Sidpara: Investigations into abrasive flow finishing of complex workpieces using FEM, wear 267 (2009), p.71.

DOI: 10.1016/j.wear.2008.11.005

[7] Takashi Sato, Stephen Wan and Yu Jing Ang, Study of process characteristics of Abrasive flow machining (AFM) for Ti-6Al-4V and validation with process model, Advanced Materials Research, 797 (2013) 411-416.

DOI: 10.4028/www.scientific.net/amr.797.411

[8] S. Wan, Y. J. Ang, T. Sato, G. C. Lim, Process modeling and CFD simulation of two-way abrasive flow machining, The international Jounal of Advanced Manufacturing Technology, 71, 5-8 (2014) 1077-1086.

DOI: 10.1007/s00170-013-5550-4