Research Papers

The Mechanisms of Material Removal in the Fluidized Bed Machining of Polyvinyl Chloride Substrates

[+] Author and Article Information
M. Barletta

e-mail: barletta@ing.uniroma2.it

F. Trovalusci

Dipartimento di Ingegneria Industriale,
Università degli Studi di Roma Tor Vergata,
Via del Politecnico 1,
00133 Roma, Italy

A. Gisario

Dipartimento di Ingegneria
Meccanica ed Aerospaziale,
“La Sapienza” Università degli Studi di Roma,
Via Eudossiana 18,
00184 Roma, Italy

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received May 27, 2012; final manuscript received September 29, 2012; published online January 7, 2013. Assoc. Editor: Tony Schmitz.

J. Manuf. Sci. Eng 135(1), 011003 (Jan 07, 2013) (11 pages) Paper No: MANU-12-1162; doi: 10.1115/1.4007956 History: Received May 27, 2012; Revised September 29, 2012

In this paper, the mechanisms of material removal during the fluidized bed machining (FBM) of polymeric substrates are analyzed. Cylindrical components composed of polyvinyl chloride (PVC) were exposed to the impact of abrasives while rotating at high speed within a fluidization column. The interaction between the Al2O3 abrasive media and the PVC surfaces was studied to identify the effect of the main process parameters, such as the machining time, the abrasive mesh size, and the rotational speed. The change in the surface morphology as a function of the process parameters was evaluated using field emission gun—scanning electron microscopy (FEG-SEM) and contact gauge profilometry. An improvement in the finishing of the processed surfaces was achieved, and the related mechanisms were identified. The roles of the impact speed and the contact conditions between the abrading particles and the substrate were also investigated.

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Fig. 1

AFB apparatus for machining of rotating axisymmetric components

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Fig. 2

Morphology of sample surfaces (a) before machining and after machining at 12,000 rpm: (b) 20 mesh; (c) 20 + 46 mesh; (d) 20 + 46 + 80 mesh

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Fig. 3

Distribution of the stresses during machining: (a) inferred mechanism; (b) SEM image of a groove

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Fig. 4

Morphology of sample surfaces (a) before machining and after machining at 12,000 rpm; (b) 20 mesh; (c) 20 + 46 mesh; (d) 20 + 46 + 80 mesh

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Fig. 5

Morphology of sample surfaces (a) before machining and after the complete machining cycle (20 + 46 + 80 mesh) at (b) 3000 rpm; (c) 6000 rpm; (d) 12,000 rpm

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Fig. 6

3D maps (a) before machining and after machining at 12,000 rpm, (b) 20 mesh; (c) 20 + 46 mesh; (d) 20 + 46 + 80 mesh

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Fig. 7

3D maps (a) before machining and after the complete machining cycle (20 + 46 + 80 mesh size); (b) 3000 rpm; (c) 6000 rpm; (d) 12,000 rpm

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Fig. 8

Roughness profiles (a) 3000 rpm; (b) 6000 rpm; (c) 12,000 rpm; (d) comparison after machining with Al2O3 of 80 mesh size. A vertical offset (15 μm) was applied to improve the profiles readability.

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Fig. 9

Roughness parameters at (a) 3000 rpm; (b) 6000 rpm; (c) 12,000 rpm



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