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Research Papers

Elastic Impact of Abrasives for Controlled Erosion in Fine Finishing of Surfaces

[+] Author and Article Information
V. S. Sooraj

e-mail addresses: sooraj@iist.ac.in and soorajvsuren@gmail.com

V. Radhakrishnan

e-mail addresses: radhakrishan@iist.ac.in and vprmfg@hotmail.comDepartment of Aerospace Engineering,
Indian Institute of Space Science
and Technology (IIST),
Thiruvananthapuram,
Kerala 695547, India

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received August 3, 2012; final manuscript received August 30, 2013; published online September 23, 2013. Assoc. Editor: Y. B. Guo.

J. Manuf. Sci. Eng 135(5), 051019 (Sep 23, 2013) (12 pages) Paper No: MANU-12-1234; doi: 10.1115/1.4025338 History: Received August 03, 2012; Revised August 30, 2013

Finishing of surfaces using free abrasive impingement is one of the constructive applications of erosive wear, well suited for complex shaped engineering components with difficult-to-access surfaces. Low velocity impact of abrasives in a fluidized bed is reported as a promising choice to impart fine finish on the target surface. An improved methodology to control the erosion and to achieve ultra fine finish through elastic impact of abrasives, using a carrier type-fluidized abrasive finishing, is discussed in this paper. Using the basic concepts of impact theory and contact mechanics, a revised mathematical model to express the depth of erosion as a function of material properties of target and erodent is proposed. Modification in erodent abrasive to introduce an elastic nature to the impact is described in detail using the theoretical model. This is substantiated through a particle-dropping experimental study. The effect of multiple impacts in a practical situation is also discussed through a detailed experimental study, clearly demonstrating the concepts of elastic impact erosion for surface finishing.

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Figures

Grahic Jump Location
Fig. 1

Expected mechanism of erosion in ductile material: (a) Elastic/plastic deformation at the interface and (b) indentation created by the impact

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Fig. 2

Expected mechanism of erosion in brittle material: (a) Growth of cone crack and median cracks, (b) closure of median crack and creation of lateral cracks, and (c) eroded crater formed by impact

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Fig. 4

The resolution of impingement velocities

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Fig. 5

The resolution of rebound velocities

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Fig. 6

Shape of actual grit and the consideration of shape factor

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Fig. 7

The details of Particle-dropping experimental setup: (a) Schematic diagram and component details and (b) an exploded view and photograph

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Fig. 8

The details of relocating plate and fixture

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Fig. 9

The abrasive holder design for direct and elastic impacts: (a) Abrasive holder without rubber pad (representing direct abrasive impingement) and (b) abrasive holder with rubber pad (simulating abrasives in an elastic medium)

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Fig. 10

Two Dimensional surface profile before and after the pilot experiment: (a) Initial surface profile, (b) profile after impact without rubber pad (dropped from a height 0.1 m), and (c) profile after impact with rubber pad (Ø 2 mm grit dropped from a height 0.1 m)

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Fig. 11

Comparison of 3D surface images of the eroded crate (drop height = 0.1 m): (a) Initial profile (Sv = 2.304 μm, Sa = 0.076 μm, Sz = 8.376 μm), (b) without rubber pad, and (c) with rubber pad

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Fig. 12

Comparison of 2D surface profile of the eroded crater (drop height = 0.1 m): (a) Surface profile of the crater without the presence of elastic pad and (b) profile of the crater formed by elastic impact with the presence of elastic pad

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Fig. 13

The effect of elastic impact on glass: (a) Image of the crack observed in glass (without elastic medium) and (b) image of the crack observed in glass (with elastic medium)

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Fig. 14

The test rig developed for fluidized abrasive finishing: (a) Schematic and (b) photograph

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Fig.15

Direct and elastic erodent particles used for fluidization: (a) A standard abrasive grit and (b) An abrasive embedded elastomeric particle

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Fig. 16

The expected effect of multiple impacts on surface profile

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Fig. 17

The effect of multiple elastic impacts on the surface profile: (a) Initial profile (Ra value 0.278 μm), (b) profile after direct abrasive impingement in fluidized bed (Ra value 0.074 μm), (c) profile after the proposed elastic impact—Trial 1 (Ra value 0.029 μm), and (d) profile after the proposed elastic impact—Trial 2 (Ra value 0.030 μm)

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