Characterization Of Deburring By Abrasive Flow Machining for AL6061

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

doi:10.20944/preprints202201.0413.v1

2022

DOI: 10.20944/preprints202201.0413.v1

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Characterization Of Deburring By Abrasive Flow Machining for AL6061

Kwang Joon Kim¹,

Young-Gwan Kim²,

Kwon-Hee Kim³

Abstract: Burrs form due to plastic deformation of materials during machining processes, such as milling and drilling. Deburring can be very difficult when the burrs are not easily accessible for removal. In this study, abrasive flow machining (AFM) was adopted for deburring the edges of milling specimens. Based on the experimental observations on AL6061 specimens, the deburring performance was characterized in terms of flow speed, the local curvature of the streamline near the burr edge, and shear stress. A new objecti… Show more

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Cited by 3 publications

References 12 publications

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Research on Electrochemical Controllable Machining Technology of Small-Sized Inner Intersecting Hole Rounding

Pang

Yan²,

Zhu³

et al. 2022

Applied Sciences

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Small-sized inner intersecting holes are a common structure for large engine nozzles, hydraulic valves, and other parts. In order to ensure the uniform and stable fluid state in the intersecting hole, it is necessary to process the fillet at the intersecting line and accurately control the fillet radius. Limited by the structure and size, the rounding of the small-sized inner intersecting hole is a technical problem, and the traditional machining methods have problems, in terms of efficiency and accuracy. In order to solve this problem, electrochemical machining technology was applied to the rounding of small-sized inner intersecting holes. According to the structure of inner intersecting holes, an electrochemical rounding processing scheme with built-in fixed cathode was designed. The electric field distribution of different cathode shapes was analyzed using finite element method software. The influence of processing voltage and processing time on the current density distribution was studied for different cathode shapes, to determine the most reasonable cathode shape. Taking the inner intersecting hole with a diameter of 2 mm as the research object, and according to the analysis of the influence of processing voltage on the processing effect, a suitable control factor for controlling the rounding was processing time, and the optimal processing voltage was obtained. The formulas of fillet radius and processing time were obtained by regression analysis and verified using machining examples. The results provide a feasible method for the accurate and controllable machining of small-sized inner intersecting hole rounding.

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Research on Electrochemical Controllable Machining Technology of Small-Sized Inner Intersecting Hole Rounding

Pang

Yan²,

Zhu³

et al. 2022

Applied Sciences

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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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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 3 publications

References 12 publications

Research on Electrochemical Controllable Machining Technology of Small-Sized Inner Intersecting Hole Rounding

Research on Electrochemical Controllable Machining Technology of Small-Sized Inner Intersecting Hole Rounding

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

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

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