Research Papers

Modeling and Simulation of Material Removal Rates and Profile Accuracy Control in Abrasive Flow Machining of the Integrally Bladed Rotor Blade and Experimental Perspectives

[+] Author and Article Information
Kai Cheng

Institute of Materials and Manufacturing,
Brunel University London,
Uxbridge UB8 3PH, UK
e-mail: kai.cheng@brunel.ac.uk

Yizhi Shao

Institute of Materials and Manufacturing,
Brunel University London,
Uxbridge UB8 3PH, UK
e-mail: yizhi.shao@brunel.ac.uk

Rodrigo Bodenhorst, Mitul Jadva

Institute of Materials and Manufacturing,
Brunel University London,
Uxbridge UB8 3PH, UK

Manuscript received April 16, 2017; final manuscript received September 23, 2017; published online November 2, 2017. Assoc. Editor: Xun Chen.

J. Manuf. Sci. Eng 139(12), 121020 (Nov 02, 2017) (8 pages) Paper No: MANU-17-1256; doi: 10.1115/1.4038027 History: Received April 16, 2017; Revised September 23, 2017

Abrasive flow machining (AFM) technology is getting more and more interest by the industry and research community particularly in the context of increasing demands for postprocessing of the additively manufactured and complex components. It is essentially important to develop an industrial feasible approach to controlling and improving the profile accuracy (form and dimensional) of components as well as their surface roughness. In this paper, a multiscale multiphysics simulation-based approach is presented to model and simulate the AFM process against the component form and dimensional accuracy control in particular. The simulation is developed in comsol which is a multiphysics computational environment. Well-designed AFM experiment trials are carried out on a purposely configured blade “coupon” to further evaluate and validate the simulations. The AFM machine and specific machining media for the experiments are provided by the industrial collaboration company, with their further industrial inputs. Both the simulation and experimental trial results illustrate that the approach is applicable to the blade profile prediction and accuracy control, which is used as a foundation for developing the simulation-based AFM virtual machining system.

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Fig. 1

Architecture of an industrial feasible virtual AFM system

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Fig. 2

The tooling/fixture design and test configuration for the blade AFM trials

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Fig. 3

Representative flow restriction in the AFM processing of IBRs

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Fig. 4

Fluid domain (gray) used in the IBR blade (black) simulation

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Fig. 5

Illustration of interactions between CFD module and simplified abrasion models

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Fig. 6

Graphical user interface of the simulation

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Fig. 7

Simulation of material removal in AFM trials

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Fig. 8

Simulated leading and trailing edge profile

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Fig. 9

Edge profile control in line with workpiece fixture configuration/design

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Fig. 10

AFM experimental setup

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Fig. 11

Simulation result of material removal in AFM trials (left) and comparison between the simulation and experimental results (right)



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