Modelling of Material Removal in Abrasive Flow Machining
Eckart Uhlmann and Simon Roßkamp
Institute for Machine Tools and Factory Management, Technische Universität Berlin
Pascalstraße 8-9, 10587 Berlin, Germany
Trends like lightweight construction and functional integration lead to more and more complex workpieces. Often, these workpieces must be finished after machining. Especially inner contours are difficult to finish. Hence, only a few manufacturing techniques are suitable for deburring, edge rounding and polishing of inner contours. An appropriate solution is abrasive flow machining (AFM), in which a highly viscous fluid with abrasive grains is used. Despite the wide usage of AFM in industry, the knowledge about the fundamentals of abrasive flow machining processes is limited. After elaborated test series new findings concerning the surface integrity are presented in this paper. This is done in terms of the regressive development of the surface roughness on the one hand and in terms of the generated edge rounding on the other hand. In this context, it is found that there is a factor of approximately 16 between the chipped material at the edge and the chipped material at the surface. This factor is nearly constant during the processing time. Finally, using the results of the studies, the correlation between the processing parameters, surface roughness, edge rounding, and material removal rate can be characterized. Moreover, these new findings can be transferred to a comprehensive process model, which is the basis for a reliable process simulation. Owing to this progress, predictions of the processing results of AFM will be possible.
-  C. A. Balman, “Honing Apparatus,” U.S. Patent 3, 039, 234, 1962.
-  M. Wu and H. Gao, “Experimental study on large size bearing ring raceways’ precision polishing with abrasive flowing machine (AFM) method,” Int. J. Adv. Manuf. Technol., Vol.83, Issues 9-12, pp. 1927-1935, 2016.
-  T. Bremerstein, A. Potthoff, A. Michaelis, C. Schmiedel, E. Uhlmann, B. Blug, and T. Amann, “Wear of abrasive media and its effect on abrasive flow machining,” Wear, Vols.342-343, pp. 44-51, 2015.
-  V. Jain and S. Adsul, “Experimental investigations into abrasive flow machining (AFM),” Int. J. Machine Tools & Manufacture, Vol.40, No.7, pp. 1003-1021, 2000.
-  L. Fang, K. Sun, and Q. Cen, “Particle movement patterns and their prediction in abrasive flow machining,” Tribotest, Vol.13, No.4, pp. 195-206, 2007.
-  V. Mihotovic, “Modellbasierte Prozessauslegung des Druckfließläppens am Beispiel keramischer Werkstoffe,” E. Uhlmann (Eds.), “Berichte aus dem Produktionstechnischen Zentrum Berlin,” Doctoral thesis, Technische Universität Berlin, Fraunhofer, 2012.
-  E. Uhlmann and S. Roßkamp, “Definiertes Kantenrunden durch Strömungsschleifen,” wt Werkstattstechnik Online, Vol.106, No.6, pp. 400-406, 2016.
-  F. Klocke and H. Willms, “Methodology to describe the influence of manufacturing processes on the part functionality,” Prod. Eng., Vol.1, No.2, pp. 163-168, 2007.
-  K. Göv, O. Eyercioglu, and M. Cakir, “Hardness Effects on Abrasive Flow Machining,” J. Mech. Eng., Vol.10, No.59, pp. 626-631, 2013.
-  F. Klocke, S. Buchholz, and J. Stauder, “Technology chain optimization: a systematic approach considering the manufacturing history,” Prod. Eng., Vol.8, No.5, pp. 669-678, 2014.
-  H. Szulczynski, “Verfahrensgrundlagen und Technologie des Hubschleifens mit viskosen Medien,” E. Uhlmann (Eds.), “Berichte aus dem Produktionstechnischen Zentrum Berlin,” Doctoral thesis, Technische Universität Berlin, Fraunhofer, 2007.
-  J. Rech, “Influence of cutting edge preparation on the wear resistance in high speed dry gear hobbing,” Wear, Vol.261, Issues 5-6, pp. 505-512, 2006.
-  S. Trengove, “Using abrasive flow machining (AFM) to (a) increase the fatigue strength of diesel injection equipment and (b) to generate high discharge co-efficient diesel injection holes,” Conf. Fuel Inject. Syst. Proc., Vol.12, pp. 33-43, 2003.
-  I. S. Jawahir, E. Brinksmeier, R. M’Saoubi, D. K. Aspinwall, J. C. Outeiro, D. Meyer, D. Umbrello, and A. D. Jayal, “Surface integrity in material removal processes,” Recent Advances. CIRP Annals – Manufact. Techn., Vol.60, No.2, pp. 603-626, 2011.
-  A. De Waele, “Viscometry and plastometry,” J. Oil Color Chem. Assoc., Vol.6, pp. 33-69, 1923.
-  W. Ostwald, “Über die Geschwindigkeitsfunktion der Viskosität disperser Systeme I,” Kolloid-Zeitschrift, Vol.36, pp. 99-117, 1925.
-  E. Uhlmann, C. Schmiedel, and J. Wendler, “CFD simulation of the Abrasive Flow Machining process,” Proc. CIRP, Vol.31, pp. 209-214, 2015.
-  E. Uhlmann and S. Roßkamp, “Definiertes Kantenrunden durch Strömungsschleifen,” wt Werkstattstechnik Online, Vol.106, pp. 400-406, 2016.
-  E. Uhlmann and S. Roßkamp, “Edge rounding of heat-treatable steel by abrasive flow machining,” submitted to Advanced Materials Proc. of American Advanced Materials Congress, Miami, 2016.
This article is published under a Creative Commons Attribution-NoDerivatives 4.0 International License.