Material removal analysis of hybrid EDM-assisted centrifugal abrasive flow machining process for performance enhancement

Abstract

Finishing of metallic machine components is a prime requirement for the better performance and longer product life cycle. To get highly finished machine components, a number of conventional and non-conventional finishing processes have evolved in recent times to overcome constraints due to shape and properties of materials. This paper discusses a new hybrid technique, Thermal additive centrifugal abrasive flow machining (TACAFM) which is a combination of centrifugal forceassisted abrasive flow machining and electrical discharge machining (EDM) process. In this process abrasive particles move coaxially with workpiece and also rotate inside the hollow workpiece with the help of a rotating system and also generated thermal effect as in EDM process. Due to the movement of abrasive particles along with rotation, Coriolis effect plays a major role in determining the position of abrasives at any time. Therefore, in the present study, Coriolis component effect is incorporated in the mathematical model to predict the material removal in TACAFM. Also, its parameters, viz current, abrasive concentration, pressure, duty cycle, and rotation of electrode, were optimized using response surface methodology. A simulation model is also presented using Ansys ® 15 software to analyze the effect of temperature around the work surface when varying gap between the electrode and work surface along with rotational speed of electrode. Experimental results show a good agreement with the mathematical model. The experiments conducted on the developed process show average 44.34% improvement in material removal and average 39.74% improvement in surface finish, respectively.

Modeling and analysis of developed Thermal additive Centrifugal Abrasive Flow Machining process

“…But in actual process, if the media flow in the gap is not continuous then it will develop oxide layers on the surface which could be clearly seen through figure 13(a). The development of oxide layers on the surface reduced the electrical conductivity of the workpiece which hampered the machining process due to lesser availability of thermal energy for melting [25]. This caused reduction in the material removal which might be a reason for the variation in experimental and modeling results.…”

“…Ali et al [24] used sharp CNT particles in addition to alumina as abrasive particles in the AFM process and found significant improvement in material removal and surface finish. In the latest development in AFM process, Ali et al [25] developed a Thermal additive Centrifugal Abrasive flow machining process in which the EDM process is hybridized with the Centrifugal force assisted AFM process. EDM process developed thermal effect over the workpiece surface which reduced the force required for indentation.…”

An experimental investigation of viscosity of a newly developed natural polymer-based media for abrasive flow machining (AFM) of 3D printed ABS parts

“…The material removal is done using three distinct modes such as micro-plowing, free rubbing, and micro-cutting (Kum et al, 2020;Dixit, Sharma, and Kumar, 2021c). The new surfaces in the abrasive machining process are created by random attacks of the abrasive elements over the irregularities that lie on the work surface (Walia, Shan, and Kumar, 2009;Ali et al, 2020). The extrusion pressure that is applied using the hydraulic cylinders generates the normal force as well as the "axial force" on the abrasive elements.…”

Quality prediction of polygonal helical curved tube by abrasive flow precision machining

“…Chawla et al placed an electromagnet on the outer wall of the workpiece during AFM, and studied the in uence of magnetism on the effect of processing [12]. Ali et al studied the in uence of centrifugal force assisted AFM, and the experimental results showed that this method had a great bene cial effect on material removal and surface quality of the workpiece [13].…”