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research-article

Experimental, Theoretical and Simulation Comparative Study of Nano Surface Roughness Generated during Abrasive Flow Finishing Process

[+] Author and Article Information
Sachin Singh

Department of Mechanical Engineering, Indian Institute of Technology Guwahati, 781 039, India
ssingh@iitg.ernet.in

Deepu Kumar

Department of Mechanical Engineering, Indian Institute of Technology Guwahati, 781 039, India
deepu144103100@gmail.com

Mamilla Ravi Sankar

Department of Mechanical Engineering, Indian Institute of Technology Guwahati, 781 039, India
evmrs@iitg.ernet.in

1Corresponding author.

ASME doi:10.1115/1.4035417 History: Received September 07, 2016; Revised December 02, 2016

Abstract

Abrasive flow finishing (AFF) is one of the advanced finishing processes used mainly for finishing of complex surface features. Nano finishing of aluminium alloys are difficult using conventional finishing processes because of its soft nature. So, in the current work, aluminium alloys are finished using AFF process. Since the finishing is carriedout using polymer rheological abrasive medium (medium), the finishing forces on aluminium alloy workpieces are too low compared to conventional finishing processes. Thus, this process generates nano surface roughness on aluminium alloy. By using the theoretical model, change in surface roughness (ΔRa) with respect to various AFF input parameters is studied. A new simulation model is proposed in current paper to predict the finishing forces and ΔRa during AFF process. Modeling of finishing forces generated during the AFF process is carriedout using Ansys Polyflow. These forces are used as input in the simulation model to predict ΔRa. Medium rheology decides the magnitude of the generated finishing forces in AFF process. Therefore, to predict the forces accurately, rheological properties of the medium are measured experimentally and used as input during modeling. Further, to make the simulation more realistic, abrasive particle bluntness with respect to extrusion pressure and number of strokes is considered. Because of considering these realistic conditions simulation and experimental results are in good agreement compared to theoretical results.

Copyright (c) 2016 by ASME
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