Nanofinishing of freeform surfaces using abrasive flow finishing process

Sarkar, Mithun; Jain, V. K.

doi:10.1177/0954405415599913

Cited by 36 publications

(11 citation statements)

References 35 publications

(43 reference statements)

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“…Various advanced finishing processes (AFPs) with different finishing fixtures such as magnetic abrasive finishing (MAF), 9 abrasive flow finishing (AFF), 10 magnetorheological fluid-based finishing (MRF), 11 and R-MRAFF 12–14 have been used to finish a femoral (knee joint). However, these finishing processes are time-consuming, and they are not able to ensure uniform surface finish.…”

Section: Introductionmentioning

confidence: 99%

Development of inverse replica fixture for nano-finishing of knee joint using R-MRAFF process

Nagdeve

Jain

Ramkumar

2018

Journal of Micromanufacturing

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Rotational-Magnetorheological Abrasive Flow Finishing (R-MRAFF) process is a technique of nano-finishing in general and free-form/sculptured surfaces in particular. Knee joint is one such example of free-form surface which is used by orthopedic surgeons. Knee joints are usually made of cobalt chromium alloy which is bio-compatible material, and it is difficult to finish. The present work deals with the development of an inverse replica for a knee joint. This inverse replica is used as a fixture so that the fluid can flow with constant velocity within the confined gap between the workpiece and inner surface of the fixture in order to achieve uniform nano-level finish. Using this technique, variation in the surface roughness ( Ra) over the knee joint surface can be minimized and productivity can be enhanced. The finishing efficiency of the R-MRAFF process depends on the input parameters such as extrusion pressure, number of finishing cycles, rotational speed of the magnet, etc. These parameters should be controlled and optimized for precision finishing which is the main objective of the present research work. The minimum average Ra of 52 nm is achieved from the initial average Ra of 194 nm on the knee joint surface. The percentage change in Ra (73.20%) was achieved using the proposed method.

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Section: Introductionmentioning

confidence: 99%

Development of inverse replica fixture for nano-finishing of knee joint using R-MRAFF process

Nagdeve

Jain

Ramkumar

2018

Journal of Micromanufacturing

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“…Many researches on abrasive flow machining can be found. In Sarkar and Jain’s 11 study, a uniform mirror surface of stainless steel knee joints was achieved using abrasive flow machining, and it proved the feasibility of abrasive flow machining to achieve polishing of free-form complex surfaces. Kavithaa and Balashanmugam 12 not only described nanometric surface finishing of typical prosthetic implants and an extrusion die used in bio-medical and pharmaceutical industries but also described the polishing of the industrial components used in aerospace applications and emphasized the importance of abrasive flow machining in the field of ultra-precision machining.…”

Section: Introductionmentioning

confidence: 89%

Experimental study of coverage constraint abrasive flow machining of titanium alloy artificial joint surface

Zhang

Huang

Chen

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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In order to study the machining mechanism and process of abrasive flow machining for the titanium alloy artificial joint surface, the abrasive flow machining experimental platform and the curved surface profiling flow channel were established for the machining. The influence of various process parameters (abrasive particle size, abrasive particle concentration, and processing time) and interaction factors on surface roughness and surface micro-topography of the workpiece was quantitatively evaluated through response surface analysis, and a surface roughness prediction model was established. The experimental results show that coverage constraint abrasive flow machining can significantly improve the surface quality of the titanium alloy artificial joint surface, thereby improving the wear resistance and service life of the artificial joint. Using abrasive flow machining with a smaller abrasive particle size and a larger concentration can obtain smaller surface roughness. Under the experimental conditions, the influence of process parameters on the surface roughness is in descending order of processing time, abrasive particle concentration, and abrasive particle size. And the interaction of processing time and abrasive particle size is more effective during processing. The research results can provide the basis for optimizing the flow channel structure for the abrasive flow machining of the titanium alloy artificial joint surface and have a certain guiding significance on the process optimization.

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“…The number of abrasive particles passing through any point on the workpiece surface is to be calculated. 20, 21 Given the diameter of the piston D p and the length of stroke I s , the volume of the stroke, that is, the volume of MRP fluid flowing through the channel in a single stroke ( V s ) of the piston, can be calculated as follows:…”

Section: Number Of Active Abrasive Particlesmentioning

confidence: 99%

Analysis of finishing forces and surface finish during magnetorheological abrasive flow finishing of asymmetric workpieces

Jayant

Jain

2019

Journal of Micromanufacturing

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Magnetorheological abrasive flow finishing (MRAFF) is an advanced hybrid process for producing ultrafine finished surfaces. Such surfaces reduce frictional forces and thereby minimize wear and tear to increase functional lifetime of the components. In the present research work, a model has been developed for simulating the results of MRAFF process. First, magnetic field is simulated and then a detailed study on the rheology of the magnetorheological polishing (MRP) fluid is conducted to develop a viscosity model for the flow of non-Newtonian shear thinning fluid. To calculate the forces acting in the process of material removal, the flow of MRP fluid around an asymmetric workpiece (knee joint) in a spatially varying magnetic field is simulated. Finishing forces exerted by the abrasive particles on the workpiece surface are analysed to develop a model for predicting surface roughness. A methodology has been proposed to evolve a variable correction factor to determine active abrasive particles at different locations on the workpiece surface for accurate simulation of surface finish operation. It is found that the magnetic field greatly influences the process performance by governing the viscosity of the MRP fluid and the distribution of the abrasive particles in the medium. During finishing of an asymmetric workpiece, the surface finish obtained at different locations on the workpiece surface is different. The developed model is capable to predict final surface finish within the acceptable accuracy when compared with the experimental results.

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Nanofinishing of freeform surfaces using abrasive flow finishing process

Cited by 36 publications

References 35 publications

Development of inverse replica fixture for nano-finishing of knee joint using R-MRAFF process

Development of inverse replica fixture for nano-finishing of knee joint using R-MRAFF process

Experimental study of coverage constraint abrasive flow machining of titanium alloy artificial joint surface

Analysis of finishing forces and surface finish during magnetorheological abrasive flow finishing of asymmetric workpieces

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