Development of Hybrid Forms of Abrasive Flow Machining Process: A Review

Bhardwaj, Anant; Ali, Parvesh; Walia, R. S.; Murtaza, Qasim; Pandey, Shailesh Mani

doi:10.1007/978-981-13-6412-9_5

Cited by 10 publications

(4 citation statements)

References 63 publications

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“…As shown in Figure 9, first the surface roughness decreased with increasing the extrusion pressure followed by an increasing trend. 18,23–34 As illustrated in Figure 9, by increasing the extrusion pressure from 7 to 9 MPa, the average surface roughness of the formal head decreased. Further enhancement in the extrusion pressure from 9 to 11 MPa, However, increased surface roughness which can be assigned to the elevation of the penetration depth, giving rise to a drastic in the surface roughness of the femoral head as shown in Figure 7.…”

Section: Resultsmentioning

confidence: 95%

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Optimal parameters of abrasive flow finishing for hip joint implants

Choopani

Khajehzadeh

Razfar

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Total hip arthroplasty (THA) is one of the most well-known orthopedic surgeries in the world which involves the substitution of the natural hip joint by prostheses. In this process, the surface roughness of the femoral head plays a pivotal role in the performance of hip joint implants. In this regard, the nano-finishing of the femoral head of the hip joint implants to achieve a uniform surface roughness with the lowest standard deviation is a major challenge in the conventional and advanced finishing processes. In the present study, the inverse replica fixture technique was used for automatic finishing in the abrasive flow finishing (AFF) process. For this aim, an experimental setup of the AFF process was designed and fabricated. After the tests, experimental data were modeled and optimized to achieve the minimum surface roughness in the ASTM F138 (SS 316L) femoral head of the hip joint through the use of response surface methodology (RSM). The results confirmed uniform surface roughness up to the range of 0.0203 µm with a minimum standard deviation of 0.00224 for the femoral head. Moreover, the spherical shape deviation of the femoral head was achieved in the range of 7 µm. The RSM results showed a 99.71% improvement in the femoral head surface roughness (0.0007) µm under the optimized condition involving the extrusion pressure of 9.10 MPa, the number of finishing cycles of 95, and SiC abrasive mesh number of 1000.

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Section: Resultsmentioning

confidence: 95%

“…They reported a surface roughness of 0.039 mm for the femoral head. Despite the significant advantages of the AFF process, [18][19][20][21][22][23][24][25] the non-uniform surface finish was seen in the microscopic images; indicating that the fixture was not designed according to the geometry of the femoral head.…”

Section: Introductionmentioning

confidence: 99%

Optimal parameters of abrasive flow finishing for hip joint implants

Choopani

Khajehzadeh

Razfar

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Ali et al [19] reviewed various researches on AFM which uses a viscoelastic media and semisolid media which can support various abrasive based finishing process including both magnetic and non-magnetic based finishing process. Bhardwaj et al [20] compiled the researches which contained the use of viscoelastic media in various hybrids of abrasive flow machining process, the researchers also commented on the tooling and fixturing in various hybrids of AFM and the compatibility of the viscoelastic media with the hybrid process. So, it can be seen that Viscoelastic Magnetic Abrasive Finishing has a vital role in Finishing department and must be consider for effective machining operation.…”

Section: Introductionmentioning

confidence: 99%

Effect of Shape of Magnet on the Machining of Workpiece

2019

IJRTE

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Viscoelastic Magnetic Abrasive finishing has achieved a wide popularity in the field of finishing as the process is capable of finishing Non-ferrous material along with the ferrous material. With the development in technology the quality and surface finish attract more attention as compare to the machining perfection and dimensional accuracy. The present paper consists of comparison of four type of magnet available in the market and one of them as self-proposed electromagnet. A single aluminium hollow cylindrical workpiece of outer diameter as 10 mm and the inner diameter as 8 mm is finished by taking the magnet one by one whose dimensions are made according to the available literature and market and are placed as two magnetic poles with 180 degrees apparats. Ansys Maxwell 16 software was used to predict the value of maximum magnetic field on the workpiece due to the shape of the magnet and it was found that the maximum magnetic field was produced by fan shape magnet of about 0.6 Tesla. From the idea of magnetic field intensity of the workpiece, the machining ability of the magnet in viscoelastic magnetic field can be produced.

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“…"Micro-cutting" [43][44][45] Initially, in [46], the authors developed the one-way process of AFM where the medium traveled in a single direction and termed it to be the simplest type of AFM that consumes the least time during the finishing process [47][48][49][50]. It was observed that surface roughness could be minimized to 90% on the machined, cast, or EDM surface having the "dimensional tolerance" up to or ±0.005 mm [51,52].…”

mentioning

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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Development of Hybrid Forms of Abrasive Flow Machining Process: A Review

Cited by 10 publications

References 63 publications

Optimal parameters of abrasive flow finishing for hip joint implants

Optimal parameters of abrasive flow finishing for hip joint implants

Effect of Shape of Magnet on the Machining of Workpiece

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

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