Characterization of Deburring by Abrasive Flow Machining for AL6061

Kim, Kwang-Joon; Kim, Young-Gwan; Kim, Kwon-Hee

doi:10.3390/app12042048

Cited by 8 publications

(3 citation statements)

References 23 publications

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“…Kim et al have investigated the deburring of AL6061 material using the AFM process. The authors have conducted the experimental study and three-dimensional CFD simulation of the deburring process and compared both experimental as well as numerical results [123]. Fu et al have also investigated the rheological and finishing behavior of AFM media using the experimental study as well as CFD simulation study [124].…”

Section: Applicationsmentioning

confidence: 99%

Understanding the Mechanism of Abrasive-Based Finishing Processes Using Mathematical Modeling and Numerical Simulation

Hashmi

Mali

Meena

et al. 2022

Metals

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Recent advances in technology and refinement of available computational resources paved the way for the extensive use of computers to model and simulate complex real-world problems difficult to solve analytically. The appeal of simulations lies in the ability to predict the significance of a change to the system under study. The simulated results can be of great benefit in predicting various behaviors, such as the wind pattern in a particular region, the ability of a material to withstand a dynamic load, or even the behavior of a workpiece under a particular type of machining. This paper deals with the mathematical modeling and simulation techniques used in abrasive-based machining processes such as abrasive flow machining (AFM), magnetic-based finishing processes, i.e., magnetic abrasive finishing (MAF) process, magnetorheological finishing (MRF) process, and ball-end type magnetorheological finishing process (BEMRF). The paper also aims to highlight the advances and obstacles associated with these techniques and their applications in flow machining. This study contributes the better understanding by examining the available modeling and simulation techniques such as Molecular Dynamic Simulation (MDS), Computational Fluid Dynamics (CFD), Finite Element Method (FEM), Discrete Element Method (DEM), Multivariable Regression Analysis (MVRA), Artificial Neural Network (ANN), Response Surface Analysis (RSA), Stochastic Modeling and Simulation by Data Dependent System (DDS). Among these methods, CFD and FEM can be performed with the available commercial software, while DEM and MDS performed using the computer programming-based platform, i.e., “LAMMPS Molecular Dynamics Simulator,” or C, C++, or Python programming, and these methods seem more promising techniques for modeling and simulation of loose abrasive-based machining processes. The other four methods (MVRA, ANN, RSA, and DDS) are experimental and based on statistical approaches that can be used for mathematical modeling of loose abrasive-based machining processes. Additionally, it suggests areas for further investigation and offers a priceless bibliography of earlier studies on the modeling and simulation techniques for abrasive-based machining processes. Researchers studying mathematical modeling of various micro- and nanofinishing techniques for different applications may find this review article to be of great help.

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Section: Applicationsmentioning

confidence: 99%

Understanding the Mechanism of Abrasive-Based Finishing Processes Using Mathematical Modeling and Numerical Simulation

Hashmi

Mali

Meena

et al. 2022

Metals

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“…AFM can be applied to gears [1], rotor blades [2], tool blades [3], small openings [4,5], internal surfaces of waveguides and elbows [6,7], complex-shaped components, and difficult-to-access surfaces [8,9]. Furthermore, AFM is used for smoothing surfaces, remove burrs [10,11], round edges, and remove the white layer [12], and in 3D printed machine parts [13,14]. A surface roughness of Ra < 50 nm can be achieved using AFM [15,16].…”

Section: Introductionmentioning

confidence: 99%

2017A Alloy surface layer after flow burnishing with glass microspheres

Korzynska,

Zarski,

Zeglicki

et al. 2024

Int J Adv Manuf Technol

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This study presents a novel flow processing technique that uses glass microspheres instead of abrasives. The fundamentals of flow machining with glass microspheres, including microsphere flow burnishing (MFB) and the conditions necessary for cutting or plastic deformation of a surface to occur during MFB, are determined. Details on such conditions are lacking, and therefore, this study attempts to define these conditions. To this end, MFB was experimentally confirmed to be a burnishing process, and the effects of MFB and abrasive flow machining (AFM) on 2017A aluminum alloy were compared. Both processes achieved a surface roughness (Sa) of < 0.5 μm, while MFB yielded higher values of surface microhardness and compressive stress. The effects of basic process parameters on the MFB and AFM results (workpiece weight loss and Sa) were compared experimentally and the corresponding mathematical models were established. Utilizing these relationships, MFB parameters can be selected so as to obtain the most favorable surface layer for the expected operating conditions.

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“…Since the inside of the gel was filled with a high number of abrasive particles, such as silicon carbides or alumina oxides, it became a high viscosity gel medium that could induce much more intensive shear forces to abrade the working surface, and therefore, the working surface could be polished effectively during the reciprocating motion in AFM. AFM also has the ability to remove machining burrs as well as recasting layers created by wire electrical discharge machining (WEDM) [5,6]. In addition, a mixed gel is a flexible gel abrasive that can change its shape to fit a working surface during machining; therefore, complex surfaces and irregular holes can be polished efficiency and the method is widely used in industries, such as automobile, aerospace, bioengineering, mold, and semiconductor [7,8].…”

Section: Introductionmentioning

confidence: 99%

Study of the Polishing Characteristics by Abrasive Flow Machining with a Rotating Device

et al. 2022

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Since only uni-direction motion is produced by traditional abrasive flow machining (AFM), so the polishing effects of the inner hole is not easy to achieve uniform roughness of the whole surface after polishing. Therefore, in this study, a rotating device with a DC servo motor was set up in the AFM to increase the tangential forces on the machining surface, and therefore, improve the uniform surface roughness and polishing efficiency. The rotating device was designed by a group of transmission gear set and a DC servo motor to create a rotational finishing path for the abrasive medium. The rotational motion of an abrasive can create different tangential forces on the working surface, inducing a more complex polishing path than that of traditional AFM. In addition to rotational speed, a servo motor can also change rotation directions in one working process, causing an abrasive medium to create many irregular finishing paths in the AFM. The experimental results showed that the surface roughness of the workpiece was significantly decreased with an increase in the rotational speed. Additionally, the results also showed that the surface roughness (SR) of the inner hole decreased from 0.61 μm Ra to 0.082 μm Ra after 20 machining cycles, the surface roughness improvement rate reached 87% at 15 rpm rotational speed, by applying a 1.5:1 silicone gel/abrasive concentration ratio and #60 abrasive mesh in the experiments. This study created excellent polishing efficiency by using a servo rotational device with AFM to produce good surface quality.

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Characterization of Deburring by Abrasive Flow Machining for AL6061

Cited by 8 publications

References 23 publications

Understanding the Mechanism of Abrasive-Based Finishing Processes Using Mathematical Modeling and Numerical Simulation

Understanding the Mechanism of Abrasive-Based Finishing Processes Using Mathematical Modeling and Numerical Simulation

2017A Alloy surface layer after flow burnishing with glass microspheres

Study of the Polishing Characteristics by Abrasive Flow Machining with a Rotating Device

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