A Pragmatic Modeling Approach in Abrasive Flow Machining for Complex-Shaped Automotive Components

Uhlmann, Eckart; Mihotovic, Vanja; Dethlefs, Arne

doi:10.1016/j.procir.2016.03.172

Cited by 16 publications

(6 citation statements)

References 4 publications

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“…At x = 40 mm, the material removal reached a minimum and maximum SR was measured. This position was chosen to calibrate the measurement and the pressure–velocity simulation because the boundary effects at this position are minimal (Uhlmann et al , 2016).…”

Section: Resultsmentioning

confidence: 99%

Model of surface roughness and material removal using abrasive flow machining of selective laser melted channels

Ferchow

Baumgartner

Klahn

et al. 2020

RPJ

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Purpose Internal channels produced by selective laser melting (SLM) have rough surfaces that require post-processing. The purpose of this paper is to develop an empirical model for predicting the material removal and surface roughness (SR) of SLM-manufactured channels owing to abrasive flow machining (AFM). Design/methodology/approach A rheological model was developed to simulate the viscosity and power-law index of an AFM medium. To simulate the pressure distribution and velocity in the SLM channels, the fluid behavior and SR in the channels were simulated by using computational fluid dynamics. The results of this simulation were then applied to create an empirical model that can be used to predict the SR and material removal thickness. To verify this empirical model, it was applied to an actual part fabricated by SLM. The results were compared with the measurements of the SR and channel diameter subsequent to AFM. Findings The proposed model exhibits maximum deviation between the model and the measurement of −1.1% for the down-skin SR, −0.2% for the up-skin SR and −0.1% for material removal thickness. Practical implications The results of this study show that the proposed model can avoid expensive iterative tests to determine whether a given channel design leads to the desired SR after smoothing by AFM. Therefore, this model helps to design an AFM-ready channel geometry. Originality/value In this paper, a quantitatively validated AFM model was proposed for complex SLM channels with varying orientation angles.

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Section: Resultsmentioning

confidence: 99%

Model of surface roughness and material removal using abrasive flow machining of selective laser melted channels

Ferchow

Baumgartner

Klahn

et al. 2020

RPJ

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“…Aluminum (AlSi7Mg0.6) and titanium (Ti6Al4V) rectangular waveguides were fabricated with additive manufacturing. Their transmission losses were found to be two times higher than simulated values at X-band (8-12 GHz) and Ka-band (27)(28)(29)(30)(31)(32)(33)(34)(35)(36)(37)(38)(39)(40) [1,2]. For a copper (CuSn15) rectangular waveguide fabricated with AM, its transmission loss at the V-band (40-75 GHz) was four times bigger than that produced by machining [3].…”

Section: Introductionmentioning

confidence: 83%

“…Similar trends were observed in other post-processed additively manufactured surfaces. Tchoffolo-Talom and Turpault [2] found about 0.2 dB reduction in transmission loss in the band (26)(27)(28)(29)(30)(31)(32)(33)(34) in the Surtec 650 chemical treated aluminium (AS10G) waveguide surface. They also found about 2 dB reduction in transmission loss in the band (26)(27)(28)(29)(30)(31)(32)(33)(34) in the silver-plated titanium (Ti6Al4V) waveguide surface.…”

Section: Electromagnetic Performances Of Lbm As-built and Afm Finishe...mentioning

confidence: 99%

“…Tchoffolo-Talom and Turpault [2] found about 0.2 dB reduction in transmission loss in the band (26)(27)(28)(29)(30)(31)(32)(33)(34) in the Surtec 650 chemical treated aluminium (AS10G) waveguide surface. They also found about 2 dB reduction in transmission loss in the band (26)(27)(28)(29)(30)(31)(32)(33)(34) in the silver-plated titanium (Ti6Al4V) waveguide surface. Martin-Guennou et al [35] observed that transmission loss decreased about 0.2 dB in the K band (12-40 GHz) and Q band (33-50 GHz) in the gold or silver-plated aluminium (AlSi10Mg) waveguide surfaces.…”

Section: Electromagnetic Performances Of Lbm As-built and Afm Finishe...mentioning

confidence: 99%

“…However, those post-processes are limited to open surfaces. On the other hand, abrasive flow machining (AFM) was recently shown to be effective to reduce the Ra value of the internal channel surfaces [25][26][27][28][29][30][31][32]. A schematic illustration of the AFM process is given in Figure 2.…”

Section: Introductionmentioning

confidence: 99%

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Electromagnetic performance of Ti6Al4V and AlSi7Mg0.6 waveguides with laser beam melting (LBM) produced and abrasive flow machining (AFM) finished internal surfaces

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et al. 2021

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HAL is a multi-disciplinary open access archive for the deposit and dissemination of scientific research documents, whether they are published or not. The documents may come from teaching and research institutions in France or abroad, or from public or private research centers. L'archive ouverte pluridisciplinaire HAL, est destinée au dépôt et à la diffusion de documents scientifiques de niveau recherche, publiés ou non, émanant des établissements d'enseignement et de recherche français ou étrangers, des laboratoires publics ou privés.

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Inline Measurement of Process Forces and Development of a Friction Model in Abrasive Flow Machining

Uhlmann

2020

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A Pragmatic Modeling Approach in Abrasive Flow Machining for Complex-Shaped Automotive Components

Cited by 16 publications

References 4 publications

Model of surface roughness and material removal using abrasive flow machining of selective laser melted channels

Model of surface roughness and material removal using abrasive flow machining of selective laser melted channels

Electromagnetic performance of Ti6Al4V and AlSi7Mg0.6 waveguides with laser beam melting (LBM) produced and abrasive flow machining (AFM) finished internal surfaces

Inline Measurement of Process Forces and Development of a Friction Model in Abrasive Flow Machining

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