Assessment of surface quality in extrusion honing process using dimensional analysis approach

Abstract

It is critical to obtain the desired surface quality on machined parts’ internal and external portions. The estimated level of surface texture can be induced on the outer regions using traditional finish machining processes such as grinding, honing, and so on. While the problem emerges when processing miniature core components such as micro bores and inlet/outlet valves. The EH approach overcomes this limitation of the conventional finishing method. It is a novel micromachining process that extrudes pressured flow of carrier media combined with abrasives into the confined passage to generate the desired level of surface texture. Due to the abrasion process, micromachining occurs by taking away negligible stock material. The present study focus on the impact of the number of passes at the specimen’s entry and exit sides of the carrier media. The improvements in the surface finish (Ra) on both sides, i.e. entry and exit, are also evaluated. A dimensionless expression for Ra is also developed. The relation is implemented using Buckingham’s π theorem, and the developed model is compared with experimental results. SEM analysis is made to portray surface texture produced by selected