Finite element analysis of viscoelastic media used in abrasive flow machining process

Abstract

The surface roughness of a part is the most important parameter in view of tribological applications and it also affects the working life of the part during application. The abrasive flow machining (AFM) process is an advanced non-conventional finishing process, used to deburr, polish, and to remove the recast layer from the surface as well as at the edges of the components. In AFM viscoelastic media is used to finish the workpiece with close dimensional tolerance and precision. The viscoelastic media used in the AFM process is laden with abrasive particles. In the present work, a finite element analysis of viscoelastic abrasive media is performed considering the AFM process. A mixture of polyborosiloxane and silicon carbide is used as viscoelastic abrasive media and the AFM process is modeled using ANSYS Polyflow. In the analysis, the flow of viscoelastic abrasive media is assumed to follow the Maxwell model of viscoelastic fluid. The simulations were performed for varying the extrusion pressure for the finishing of an internal cylindrical surface. The results of the simulations were validated with the experimental observation and found in good agreement.