Abrasive Flow Research Articles

Experimental investigation on abrasive flow finishing of FDM printed polymeric spur gear

Experimental investigation on abrasive flow finishing of FDM printed polymeric spur gear

A forecasting model for optimizing abrasive water jet machining (AWJM) parameters based on the adaptive neuro-fuzzy inference system and meta-heuristic algorithms

Innovative materials have been steadily produced in the machining process, and it has stimulated substantial attention among researchers to assess the ideal parameters for the processing of these materials. In the manufacturing industry, conventional and modern or unconventional machining retains their imprint in delivering quality products. One of the most frequently used contemporary machining processes is abrasive water jet machining (AWJM) for cutting materials. The optimization of parameters, however, is essential to manufacturing high-quality products quickly and affordably. This study focused on optimizing the machining parameters of AWJM using the Adaptive Neuro-Fuzzy Inference System (ANFIS) by encrypting the evolutionary algorithms, including the reptile search algorithm (RSA), beetle antennae search (BAS), and particle swarm optimization (PSO). As a result of the developed methods, the surface roughness of titanium alloy (Ti–6Al–4V) during AWJM machining is predicted by considering inputs such as standoff distance, abrasive flow rate, and traverse speed, which affect the surface roughness. Based on a comparison of the prediction accuracy of the proposed methods, it was found that the combined ANFIS and RSA outperforms the others. In the simulation results, ANFIS-RSA (Adaptive Neuro-Fuzzy Inference System and Reptile Search Algorithm) yielded the most accurate estimates of surface roughness based on the RMSE (0.1241), MAE (0.0961), MAPE (0.0201), and R2 (0.9781) values. In particular, the analysis findings demonstrated that the combination of ANFIS and RSA was the most effective approach for predicting surface roughness on titanium alloy during AWJ machining.

PROCESS OPTIMIZATION BY APPLYING THE RESPONSE SURFACE METHODOLOGY (RSM) TO THE ABRASIVE SUSPENSION WATER JET CUTTING OF PHENOLIC COMPOSITES

The paper introduces the study on the cutting of the industrial composite phenolic resin, based on the thermoset materials reinforced with cotton cloth by the Abrasive Water Suspension Jet (AWSJ). The size reduction of abrasive grains during the formation of the jet and the erosion phenomenon are shown. The results of the machining process's critical factors as nozzle length, nozzle diameter, and abrasive mass flow rate on the maximal cutting depth, are indicated. To build a model of the process, the method of the response surface (RSM) was applied. The second-degree multinomial equation is selected for creating the cutting model. The research indicates the optimal control factors of the process, to achieve the best cutting depth performance.

Optimal model-based control for automated robotized abrasive blasting system

In robotic abrasive blasting operations, achieving the required surface roughness and cleanliness relies heavily on manually pre-set operational parameters. These parameters, such as stand-off distance, blasting angle, inlet air pressure, abrasive flow rate, and particle size, are set based on operator experience. However, given that optimal values for these parameters vary depending on specific blasting conditions and surface requirements, the pre-set values often fail to deliver both the desired surface quality and productivity. To address these challenges, we propose a solution employing a set of proxy models and a model predictive control system to achieve optimal operational outputs. For energy efficiency and productivity maximization, we utilize computational fluid dynamics with a multiphase flow solver to determine the optimal stand-off and offset distances, thus controlling the blasting nozzle effectively. Additionally, we build a data-driven model to obtain the optimal reference set point of air pressure at the sensor location based on the desired surface roughness. Moreover, we develop a dynamic process model to link the inlet air pressure and abrasive flow rate to the air pressure at the sensor location, which facilitates the development of a model-based control system. By applying this comprehensive approach, we evaluate and optimize the control and operational parameters to achieve the desired surface roughness and productivity targets. To validate the effectiveness of our newly developed control system and models, extensive tests are conducted both virtually (in silico) and on-site. The results confirm the stability and accuracy of the control system. In on-site reliability tests, the automated blasting system successfully delivers the desired surface roughness with a relative error of less than 5 % and a remarkable 30–50 % improvement in productivity. Overall, our innovative control system and models offer a reliable and efficient solution for robotic abrasive blasting, ensuring consistent surface quality and productivity enhancements.

Optimization of Process Parameters to Minimize the Surface Roughness of Abrasive Water Jet Machined Jute/Epoxy Composites for Different Fiber Inclinations

Composites materials like jute/epoxy exhibit high hardness and are considered as difficult-to-machine materials. As a result, alternatives to conventional machining become essential to post-process the composites. Accordingly, due to its non-thermal nature, abrasive water jet machining has recently come to be seen as one of the most promising machining methods for composite materials. In the current study, the impact of machining parameters such as traverse speed (TS), standoff distance (SOD) and abrasive mass flow rate (MFR) on machined surface roughness (Ra) has been investigated. In addition, the optimum combination of process parameters to machine a jute fiber-reinforced polymer composite with minimum Ra is predicted. The experimental results are analyzed using Taguchi and Response Surface Methodology (RSM) approaches to determine the optimum set of process parameters to achieve the lowest roughness values. Without making any changes in the machining conditions, the optimum set of values is determined for two conditions by reinforcing the fiber with 45° inclination and 90° inclination. The results reflect the different optimum combinations for each fiber inclination. For 45° fiber inclination, to achieve the minimum Ra value, the predicted combination is TS = 30 mm/min, SOD = 2 mm and MFR = 0.35 kg/min. When the fiber inclination is 90°, the predicted optimum combination is TS = 25 mm/min, SOD = 2 mm, and MFR = 0.35 kg/min. It is evident from the results that the optimum combination will be changed according to the machining conditions as well as material properties. The results confirm the effect of fiber orientation on surface roughness. The specimen with 45° fiber inclination produces a lower Ra with an average of 4.116 µm, and the specimen with 90° fiber inclination generates a higher Ra with an average of 4.961 µm.

Key technologies and development trends of the soft abrasive flow finishing method

Key technologies and development trends of the soft abrasive flow finishing method

Investigation on finishing mechanism and modelling on material removal for abrasive flow machining micro-channels with asperity surface

Investigation on finishing mechanism and modelling on material removal for abrasive flow machining micro-channels with asperity surface

A Case Study to Using Acid Soluble Abrasive Materials for Hydra Jetting Gas Well

Abstract Gas extraction is affected by the presence of condensate and water in the extraction wells, with gas flow decreasing as the liquid rate increases. In this case, it is unnecessary to increase the recovery factor by increasing the gas flow rate. That is precisely why the technique of dilating the pores of the rocks through an abrasive effect is useful in this operation. In this paper is presenting abrasive flow rate in test to dilating pores of the gas well.

A Study to Investigate the Influence of Machining Parameters on Delamination in the Abrasive Waterjet Machining of Jute-Fiber-Reinforced Polymer Composites: An Integrated Taguchi and Response Surface Methodology (RSM) Optimization to Minimize Delamination

In recent years, abrasive waterjet machining has emerged as a promising machining technique for the machining of composites because of its non-thermal nature. In the present study, the effect of machining parameters on the quality of machining has been studied and the process parameters have been optimized to machine jute-fiber-reinforced polymer composites. The design of the experiment was used to predict the combination of the input parameters for L27 experiments. Taguchi and response surface methodology (RSM) techniques were employed to analyze the experimental data and identify the optimum combination of process parameters to achieve as little delamination as possible. The results indicate that an increase in the values of the parameters traverse speed and abrasive mass flow rate leads to an increase in the damage obtained. However, an increase in the value of the parameter stand-off distance minimizes the damage produced. To achieve minimum delamination, the optimum combination of input parameters is obtained through Taguchi and RSM. For the present experimental condition, to achieve minimum delamination, the parameter traverse speed should be set at 20 mm/min, the stand-off distance should be 4 mm, and the abrasive flow rate should be set at 0.25 kg/min. The results confirm that the optimum combination of parameters obtained through both approaches is similar. This investigation results indicated a significant improvement in the cutting quality with reduced damage, achieved through the optimized process parameters. For the considered range of parameters, graphs are plotted such that any intermediate values can be anticipated within the considered range without performing any further experiments. The present work signifies the effect of fiber orientation on delamination.

A novel quantitative analysis approach for hole surface damage of ceramic matrix composites machined by abrasive waterjet

To realize low-damage hole-making machining of AWJ-machined CMC, it is necessary to achieve quantitative analysis of hole surface damage. Therefore, a novel approach to quantifying damage based on the principle of invariance of damage area is proposed in this study. The amount of total damage is attributed to the sum of the equivalent average damage lengths of the four common types of damage (peripheral compound damage, tearing damage, crack damage, and burrs damage), which are uniformly arranged inside and outside the hole in sequence according to the principle of constant area. The influence law and influence mechanism of common process parameters on the surface damage in Cf/SiC during hole making via AWJ are investigated based on the established quantitative damage analysis model. The total surface damage increases with the increase of the standoff distance, and decreases with the increase of waterjet pressure and abrasive flow rate. The most significant factor affecting the total surface damage is the standoff distance, followed by waterjet pressure and abrasive flow rate. However, the effect of traverse speed is not noteworthy. The approach of quantitative damage analysis will provide the necessary theoretical basis and technical guidance for achieving low damage hole-making surface utilizing AWJ.

An experimental and numerical analysis on the validity of Preston coefficients in mechanistic prediction methods used for abrasive flow machining (AFM)

An experimental and numerical analysis on the validity of Preston coefficients in mechanistic prediction methods used for abrasive flow machining (AFM)

FLUID CHARACTERISTICS AND POLISHING EXPERIMENT OF INCLINED HOLE ARRAY USING ABRASIVE WATER FLOW

Inclined hole arrays on superalloys have important applications in aeroengines. However, defects occur during fabrication of inclined holes using thermal drilling methods, i.e. electrical discharge drilling (EDD), including a recast layer and microcracks on the hole wall. Therefore, abrasive water flow polishing (AWFP) of a superalloy inclined hole array machined via EDD was investigated in this study. Two types of specimens were designed: a hole array of identical size and a hole array with an identical inclination angle. The fluid simulation revealed that the fluid velocity and pressure on the lower edge of the inclined hole were significantly higher than those on the upper edge when the fluid flowed forward. The fluid characteristics exhibited opposite trends when backward flow was implemented. Time-division bidirectional flow can effectively compensate for flow field nonuniformity and improve material removal consistency during polishing. The experimental results show that for inclined holes with identical inclination angles, the size expansion decreases with an increase in the hole diameter owing to the lower fluid velocity and material removal volume in the relatively larger holes. Consequently, surface roughness Ra increases with hole size. For inclined holes with identical diameters, the size expansions of the entrance and exit approach the same level; whereas, Ra decreased with an increase in the inclination angle. The hole taper slightly reduced in all cases. Using garnet abrasives with 1300 mesh size, 1.5 wt.% abrasive concentration, and 3 MPa fluid pressure, the surface roughness Ra of target holes was reduced from pre-polishing [Formula: see text] 5.0 [Formula: see text]m to approximately post-polishing 1.0 [Formula: see text]m. The recast layer on the hole wall caused by EDD was completely removed.

Morphology of Finished Brass Surface by Thermal Additive Centrifugal Abrasive Flow Machining Process Using Novel Electrode

Morphology of Finished Brass Surface by Thermal Additive Centrifugal Abrasive Flow Machining Process Using Novel Electrode

Abrasive flow machining of specimens of cast billets from austenomartensitic steel with high-viscosity media

The paper presents the results of research on abrasive flow machining of removable specimens of cast billets made of austenomartensitic steel placed in a simulator of a closed curvilinear channel. The change in the roughness and micro-hardness of the surface of the samples was evaluated. There are two stages of machining. At the first stage of machining, most of the casting skin is removed. At the second stage, the casting skin is removed completely and the base metal layer is removed. It was established that the main mechanism for removing material from the surface of a cast billet is microcutting at the level of elementary real areas of contact of individual grain micro-protrusions. According to the results of the experiments, it is recommended to use abrasive flow machining with highly viscous medium to improve the roughness and increase the micro-hardness of the inner surfaces of the closed channels of cast billets.

Surface and subsurface integrity of monocrystalline silicon in impulse-discharge driven abrasive machining

In abrasive machining of monocrystalline silicon, surface and subsurface behaviors are changed by the brittle-to-ductile removal transfer due to uncertain mechanical force, thus leading to surface micro-burr, surface roughness, subsurface residual stress, subsurface damage and so on. In mechanical diamond grinding, an impulse-discharge between wheel metal and semiconductor silicon is proposed to drive a loose-abrasive flow along with the flexible pressure for nano-scale surface removal, micro-scale mechanical removal and thermal modification. The formation behavior of abrasive-Si interface is researched to improve the surface and subsurface integrity by integrating modification, flexible removal and cut-copying. First, the surface formation procedure was modelled in relation to impulse-discharge energy, hydrodynamic pressure and loose-abrasive diameter, etc. Then, the dynamic characteristic of fixed-diamond, loose-abrasive machining as well as impulse-discharge machining was investigated in relation to the ductile-brittle transition. Finally, the surface integrity of monocrystalline silicon was investigated in hybrid machining. It is shown that the hybrid machined formation chain is formed in the abrasive-workpiece interface with cut-copying the surface profile. The impulse-discharge drives the loose-abrasive and modifies the interface by thermal ductile transition. The loose-abrasive obtains a removal force to eliminate the modified Si–O bond and expose the Si2p3/2, Si2p1/2 substrate with ductile formation. Decreasing the impulse-discharge energy and hydrodynamic pressure promote brittle to ductile transition for high surface and subsurface integrity. Accordingly, the surface integrity is subject to impulse-discharge energy, hydrodynamic pressure and loose-abrasive size. With the thermal tensile and abrasive driven effect of impulse-discharge, the residual compressive stress, surface micro-burr and subsurface damage thickness were decreased by 72 %, 65 % and 88 %, respectively. As a result, the mechanical cut-copying with impulse-discharge thermal modifying action and abrasive flow driving ensures the surface integrity and form accuracy in process.

Machinability and mechanism of abrasive flow machining ultra-precision surface with orientated grinding marks

The loud noise in electric automobile caused by the overlap between orientated grinding marks with meshing line on ground gear tooth surface becomes a big problem for both drivers and manufacturers. Relying on the excellent self-deformation features and trace material removal, the abrasive flow machining (AFM) process exhibited potential machinability for above ultra-precision ground surface. Benefiting by the pseudo network structure, the abrasive media would possess both excellent elasticity and fluid capability, which could be quantitatively reflected by storage modulus, loss modulus and shear thinning nature in rheological properties. Meanwhile, deriving from the CFD simulation, the media exhibited the steady flow velocity and shear stress at the finishing channel, potentially contributing to the finishing uniformity on the target ground channel, which was subsequently confirmed by the change of ground surface morphology and profiles at the initial and finished state. Most convex peaks and concave valleys have been effectively subdued and whittled, leading to a rather smoother surfaces than initial ones. Besides, on account of the different collision position between grains with convex peaks, the finishing mechanism on ground surfaces with orientated marks could be elaborated as the transition effect from directly fractured material removal on convex peak cusp into plastic deformation on residual convex peaks. Combining with the interaction between continuous matrix and discrete grains in flow field, the mechanics on single grain was systematically investigated to establish the material removal theoretical model. Generally, the AFM technique exhibited the stunning machinability on ultra-precision ground surface.

On Characterization of Shear Viscosity and Wall Slip for Concentrated Suspension Flows in Abrasive Flow Machining.

In the realm of abrasive flow machining (AFM), precise finishing and maintaining dimensional accuracy have remained challenging due to non-uniformities in the AFM process and complexities associated with the abrasive media's shear viscosity and wall slip behavior. By addressing these challenges, this study introduces a comprehensive framework, combining theoretical foundations, measurement techniques, and experimental setups. Utilizing capillary flow, a novel compensation strategy is incorporated within the Mooney method to counter entrance pressure drop effects. This enhanced capillary flow method emerges as a promising alternative to the conventional Cox-Merz empirical rule, enabling precise characterization of wall slip behavior and shear viscosity, particularly at elevated shear rates. The abrasive media exhibit a Navier nonlinear wall slip, as highlighted by the Mooney method. Rigorous verification of the proposed methodologies and models against supplemental experiments showcases a high degree of congruence between predicted and observed results, emphasizing their accuracy and broad application potential in AFM. This research illuminates the intricacies of the abrasive media's behavior, accentuating the need for meticulous characterization, and provides a robust foundation for genuine modeling and predictions in material removal within AFM.

Finishing and Wear analysis of 3D-Printed Workpiece Through Centrifugal Force-Assisted Abrasive Flow Machining

Finishing and Wear analysis of 3D-Printed Workpiece Through Centrifugal Force-Assisted Abrasive Flow Machining

Influence of abrasive water jet machining process parameters on accuracy of hole dimensions in glass fiber reinforced polymer composites

Experimental investigation was done in this work to determine the effects of abrasive water jet (AWJ) machining process variables such abrasive grain size, standoff distance (SOD), abrasive flow rate, hydraulic pressure, material thickness, and fiber orientation on dimensional quality features. The Taguchi L27 orthogonal array is used in the experiment design. The Abrasive Water Jet Machining (AWJM) process parameters and response parameters are correlated using Taguchi's ANOVA and SEM pictures to statistically analyze the experimental outcomes. According to the experimental findings, the two most important variables affecting dimensional accuracy are material thickness and standoff distance.

Evaluation of Geometric Defects Produced in Abrasive Water Jet Drilling of Steel S275JR

Drilling of metal alloys is an operation that is still performed today in many industrial sectors such as aeronautics, automotive or civil engineering. This is mainly due to the high number of mechanical joints that must be made in structural elements. However, it is known that conventional drilling operations can generate defects on the machined surface mainly due to the effect of temperature on the tool and the material. For this reason, a non conventional process such as abrasive water jet machining (AWJM) is ideal for this type of operation. The decrease in temperature along the process minimizes the defects generated while keeping a high surface finish on the machined part. Therefore, this research has been carried out, where a 2 mm thick S275JR steel has been drilled by abrasive water jet. An experimental methodology has been developed to carry out the drilling. The input parameters include hydraulic pressure (P), stand of distance (SOD), abrasive flow rate (AMF) and traverse speed of the tool head (TS). In order to carry out the experiment satisfactorily, micro-drilling trials have been carried out leaving the TS parameter fixed in order to know the behavior of the material against the kinetic energy presented by the water jet equipment. These holes have been analyzed by means of the geometrical defects obtained in the form of diameter and kerf taper angle. Finally, the most relevant conclusions of the research have been developed, where it is emphasized that kerf taper (KT) angle increases drastically with the increase in SOD, giving greater results in area and with a greater amount of deformations and projections.