Research trends in abrasive flow machining: A systematic review

Dixit, Nitin; Sharma, Varun; Kumar, Pradeep

doi:10.1016/j.jmapro.2021.03.009

Cited by 80 publications

(21 citation statements)

References 148 publications

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“…The flexibility of abrasive media makes this process suitable for finishing complex geometries (Nagdeve et al, 2020). AFM has numerous industrial and material applications (Dixit et al, 2021b). It effectively finishes gears, biomedical implants, automotive nozzles, turbine blades, EDMed parts, micro geometries and advanced materials.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigations into abrasive flow machining (AFM) of 3D printed ABS and PLA parts

Dixit

Sharma²,

Kumar

2021

RPJ

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Purpose The surface roughness of additively manufactured parts is usually found to be high. This limits their use in industrial and biomedical applications. Therefore, these parts required post-processing to improve their surface quality. The purpose of this study is to finish three-dimensional (3D) printed acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) parts using abrasive flow machining (AFM). Design/methodology/approach A hydrogel-based abrasive media has been developed to finish 3D printed parts. The developed abrasive media has been characterized for its rheology and thermal stability using sweep tests, thermogravimetric analysis (TGA) and differential thermal analysis (DTA). The ABS and PLA cylindrical parts have been prepared using fused deposition modeling (FDM) and finished using AFM. The experiments were designed using Taguchi (L9 OA) method. The effect of process parameters such as extrusion pressure (EP), layer thickness (LT) and abrasive concentration (AC) was investigated on the amount of material removed (MR) and percentage improvement in surface roughness (%ΔRa). Findings The developed abrasive media was found to be effective for finishing FDM printed parts using AFM. The microscope images of unfinished and finished showed a significant improvement in surface topography of additively manufactures parts after AFM. The results reveal that AC is the most significant parameter during the finishing of ABS parts. However, EP and AC are the most significant parameters for MR and %ΔRa, respectively, during the finishing of PLA parts. Practical implications The FDM technology has applications in the biomedical, electronics, aeronautics and defense sectors. PLA has good biodegradable and biocompatible properties, so widely used in biomedical applications. The ventilator splitters fabricated using FDM have a profile similar to the shape used in the present study. Research limitations/implications The present study is focused on finishing FDM printed cylindrical parts using AFM. Future research may be done on the AFM of complex shapes and freeform surfaces printed using different additive manufacturing (AM) techniques. Originality/value An abrasive media consists of xanthan gum, locust bean gum and fumed silica has been developed and characterized. An experimental study has been performed by combining printing parameters of FDM and finishing parameters of AFM. A comparative analysis in MR and %ΔRa has been reported between 3D printed ABS and PLA parts.

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Section: Introductionmentioning

confidence: 99%

Experimental investigations into abrasive flow machining (AFM) of 3D printed ABS and PLA parts

Dixit

Sharma²,

Kumar

2021

RPJ

Self Cite

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“…Abrasive flow machining (AFM) has been mainly used for polishing and deburring [10,11]. Dixit classified AFM techniques into one-way, two-way, multi-way, and orbital processes [12]. These AFM processes employ a high-viscosity medium, incurring a high drive load [13].…”

Section: Introductionmentioning

confidence: 99%

Characterization Of Deburring By Abrasive Flow Machining for AL6061

Kim¹,

Kim²,

Kim³

2022

Preprint

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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 objective function that can predict the extent of deburring is proposed based on these characteristics and validated through experiments. Based on this new objective function, a prediction of deburring performance on the burr edge of the intersecting holes with offset was performed. The results between the predicted and experimental observation results were in reasonable agreement.

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“…Pure waterjets are used to cut soft materials such as foods, medicines, fabrics, or wood. Such waterjets cannot cut metals or hard composites, so an abrasive waterjet (AWJ) is required [1][2][3][4][5][6][7][8][9][10][11][12][13][14][15][16][17][18]. Water at 300-600 MPa and abrasive particles (#50-200 mesh) are mixed, ejected at high speed via a nozzle (bore size 0.24-0.40 mm), and the material is cut by the jet stream.…”

Section: Introductionmentioning

confidence: 99%

Nozzle Condition Monitoring System Using Root Mean Square of Acoustic Emissions during Abrasive Waterjet Machining

Kim

et al. 2022

JMMP

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Machining of difficult-to-cut materials such as titanium alloys, stainless steel, Inconel, ceramic, glass, and carbon fiber-reinforced plastics used in the aerospace, automobile, and medical industries is being actively researched. One non-traditional machining method involves the use of an abrasive waterjet, in which ultra-high-pressure water and abrasive particles are mixed and then ejected through a nozzle, and the thin jet stream cuts materials. The nozzle greatly affects the machining quality, as does the cutting tool of general machining, so it is very important to monitor the nozzle condition. If the nozzle is damaged or worn, or if the bore size increases or the bore becomes clogged with abrasive, the material may not be cut, or the surface quality of the cut may deteriorate. Here, we develop a nozzle monitoring system employing an acoustic emission sensor that detects the nozzle condition in real time.

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Research trends in abrasive flow machining: A systematic review

Cited by 80 publications

References 148 publications

Experimental investigations into abrasive flow machining (AFM) of 3D printed ABS and PLA parts

Experimental investigations into abrasive flow machining (AFM) of 3D printed ABS and PLA parts

Characterization Of Deburring By Abrasive Flow Machining for AL6061

Nozzle Condition Monitoring System Using Root Mean Square of Acoustic Emissions during Abrasive Waterjet Machining

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