Abrasive Process Research Articles

Comparative modeling of abrasive waterjet machining process based on OA-Taguchi and D-optimal approach and optimization using simulated annealing algorithm

In this study a technique has been addressed in order to model and optimize AWJM process. The required data for modeling and optimization purposes has been achieved using orthogonal array Taguchi (OA-Taguchi), D-optimal techniques and their combination based on design of experiments (DOE) approach. Water pressure, abrasive flow rate, machining speed, and machining gap are the process variables considered in this study. To evaluate the process, surface roughness (SR) has been taken into account as the process characteristic. Regression modeling using which has been turned into a widely used method has been employed to establish a relationship between process input variables and output characteristic. Analysis of variance (ANOVA) has been employed to evaluate the adequacy of the proposed models among which the most fitted and proper ones selected as the authentic representative of the process and considered as the process objective function to be optimized. Next, to optimize the objective function in order to get the desired characteristic (SR), the proposed model has been embedded into simulated annealing (SA) algorithm. Based on the computational results (less than 4% error), the proposed procedure is quite effective in modeling and optimization of the process.

Insights of abrasive water jet polishing process characteristics and its advancements

Nowadays, Abrasive water jet (AWJ) machining is used in the manufacturing Industries as cutting, turning, milling and drilling processes. The application of this technology is further extended into polishing application. However, the cutting nature of the AWJ have produced the inappropriate surface conditions. Recently, the hybrid AWJ namely, Ultrasonic Assisted Abrasive Water Jet Polishing (UAAWJP) is mainly developed for polishing the complex shapes and the internal features of both metal and non-metals. Compared with other polishing technologies, UAAWJP has several advantages such as improvement in performance efficiency, higher kinetic energy, better surface quality, high precision, ease to control and absence of thermal distortions. The hybrid process is involved with variety of factors such as ultrasonic waves (frequency and vibration), abrasive particle type &size, jet pressure, traverse rate, abrasive mass flow rate, standoff distance, nozzle geometry, jet impact angle and processing time. However, the usage of conventional AWJ and UAAWJP techniques is scarce due to the lack of understanding of process mechanism and technical publications. It is mentioned that review article on AWJ polishing operations has not been published till date. Therefore, the present work is deals with the insights of previous studies on AWJ polishing and it advancements particularly in UAAWJP, and the results are presented with in view of process mechanism, features, benefits, effects and applications, and the results are also compared with other polishing techniques. The outcome of this study can also provide the better understanding and confident to the researchers and scientists on UAAWJP for further advancements and applications on it.

Analysis of material removal of Inconel 718 cylinder using magnetic abrasive finishing process assisted with chemical etching

Application of Inconel 718 cylinders have been uprising with the up gradation of requirement of super alloys in this advance technological world. Although Inconel 718 possesses superior mechanical properties resulting into excellent performance in extreme environmental conditions but on the other hand make it difficult to machine and finish with available machining processes. This investigation has been used for the analysis of material removal of Inconel 718 cylinder using magnetic abrasive finishing process assisted with chemical etching. Finishing process has been conducted on 155 mm long and 5.7 mm thick Inconel 718 cylinder under specified investigating variable parameters such as duration of processing, work pole gap, abrasive weight percentage, and size of abrasive particles and concentration of etchant keeping certain factors as constant like rotational speed, etching temperature. Impact of processing variables represent through surface microstructure.

Assessment of Shoreline Transformation Rates and Landslide Monitoring on the Bank of Kuibyshev Reservoir (Russia) Using Multi-Source Data

This study focuses on the Kuibyshev reservoir (Volga River basin, Russia)—the largest in Eurasia and the third in the world by area (6150 km2). The objective of this paper is to quantitatively assess the dynamics of reservoir bank landslides and shoreline abrasion at active zones based on the integrated use of modern instrumental methods (i.e., terrestrial laser scanning—TLS, unmanned aerial vehicle—UAV, and a global navigation satellite system—GNSS) and GIS analysis of historical imagery. A methodology for the application of different methods of instrumental assessment of abrasion and landslide processes is developed. Different approaches are used to assess the intensity of landslide and abrasion processes: the specific volume and material loss index, the planar displacement of the bank scarp, and the planar-altitude analysis of displaced soil material based on the analysis of slope profiles. Historical shoreline position (1958, 1985, and 1987) was obtained from archival aerial photo data, whereas data for 1975, 1993, 2010, 2011, and 2012 were obtained from high-resolution satellite image interpretation. Field surveys of the geomorphic processes from 2002, 2003, 2005, 2006, 2014 were carried out using Trimble M3 and Trimble VX total stations; in 2012–2014 and 2019 TLS and UAV surveys were made, respectively. The monitoring of landslide processes showed that the rate of volumetric changes at Site 1 remained rather stable during the measurement period with net material losses of 0.03–0.04 m−3 m−2 yr−1. The most significant contribution to the average annual value of the material loss was snowmelt runoff. The landslide scarp retreat rate at Site 2 showed a steady decreasing trend, due to partial overgrowth of the landslide accumulation zone resulting in its relative stabilization. The average long-term landslide scarp retreat rate is—2.3 m yr−1. In 2019 earthworks for landscaping at this site have reduced the landslide intensity by more than 2.5 times to—0.84 m yr−1.

Optimization of Abrasive Water Jet Machining of SiC Reinforced Aluminum Alloy Based Metal Matrix Composites Using Taguchi-DEAR Technique.

Since the importance of introducing new engineering materials is increasing, the need for machining such higher strength materials has also considerably increased. In the present research, an endeavor was made to introduce a Taguchi–DEAR methodology for the abrasive water-jet machining process, while machining a SiC-reinforced aluminum composite. Material removal rate, taper angle, and surface roughness were considered as the quality measures. The optimal arrangement of input process factors in the AWJM process was found to be 2800 bar (WP), 400 mg/min (AF), 1000 mm/min (FR), and 4 mm (SOD), among the chosen factors, with an error accuracy of 0.8%. The gas pressure had the most significance for formulating the performance measures, owing to its ability to modify the impact energy and crater size of the machined specimen.

Kajian Energi Gelombang Laut Di Daerah Abrasi Serangai, Bengkulu Utara Melalui Pengamatan Tinggi Gelombang Laut

<p class="AbstractText"><span lang="EN-AU">The Serangai area, Batik Nau District, North Bengkulu has the highest average abrasion speed of 20 m/year. The abrasion could cause the coastal area to erode the coastline till several tens of meters. The purpose of this study was to determine the height of the ocean waves and to determine the energy of the ocean waves that has the potential to accelerate the abrasion process in the Serangai area. The research was carried out on November 5-7, 2018 in the Serangai beach area at a depth of 5 m using SBE 26 Plus Seagauge Wave equipment. The results showed that the observed wave height was between 0.8-1.6 m with a significant wave height (Hs) of 1.38 m. In addition, the wave period ranges from 5-11 s with a significant wave period (Ts) of 8.2 s. The result also shows that the maximum wave height of 1.6 m occurred on November 7, 2018 with maximum wave energy of 1800 J/m<sup>2</sup>. This result can perhaps accelerate the abrasion process in the Serangai area. It can also be seen that the wave height in the Serangai region is higher than in several other areas in Indonesia. However, it is necessary to continue observing the wave height to see the seasonal variations in sea wave height in Serangai area.</span></p>

Study on magnetic abrasive finishing process of AlSi10Mg alloy curved surface formed by selective laser melting

In this paper, AlSi10Mg alloy powder is selected as the forming powder of Selective laser melting technology, and the AlSi10Mg alloy SLM curved surface sample is constructed by setting the internal and external layering parameters. In view of the relatively rough surface roughness of SLM technology molded parts, this paper selects the magnetic finishing technology with higher flexibility characteristics to perform surface finishing and finishing on the formed curved surface samples. Explore the feasibility of magnetic finishing technology on the finishing of SLM shaped curved parts, and test and analyze the surface roughness, surface hardness and hydrophobicity of the finishing permanent magnet tools and the curved surface samples before and after finishing. Finally, it was found that the use of a 75° trapezoidal slotted permanent magnet finishing tool to absorb spherical Al2O3 magnetic abrasives for flexible finishing of AlSi10Mg alloy SLM shaped curved surface samples can achieve better finishing results. In this paper, the orthogonal experiment method is used to optimize the finishing experiment. It is found that the finishing parameters of the spindle speed is 1800 r/min, the feed rate is 5 mm/min, the gap is 2 mm, and the abrasive consumption is 7 g to form the AlSi10Mg alloy SLM. The surface roughness Ra = 0.279 μm can be obtained by magnetic finishing of the curved sample, and the surface morphology of the sample has been greatly improved. At the same time, it is found that the magnetic finishing technology improves the surface roughness of the AlSi10Mg alloy SLM forming surface sample, while it does not change the surface hardness of the sample, but it can significantly improve the hydrophobicity of the sample surface.

A Metallographic Preparation Method for Three-Dimensional Microstructural Characterization of Machining Chips

Abstract Chip formation is an important indicator of machining processes. Statistical characterization of machining chips’ geometric features can offer crucial information for evaluating the stability and productivity of the machining processes. In abrasive machining processes, an abundance of small chips are produced by the vast number of abrasives exposed to the cutting surfaces. Geometric features of abrasives, such as shape, dimension, and distribution, may be hierarchically passed on to the chips. Similar to those of the abrasives, geometric features of the chips may also vary to a certain extent and conform to some statistical distribution. To verify these characteristics, a metallographic preparation method in connection with chips formed in abrasive machining processes is proposed in this study. Challenges in collecting and segmenting chips have been successfully overcome through several steps using ultrasonic bath cleaning and powder cold embedding methods. Finally, a considerable amount of chips was formed and uniformly embedded in a resin mold, ready for microscopic characterization.

A Novel Manufacturing Process for Glass THGEMs and First Characterisation in an Optical Gaseous Argon TPC

This paper details a novel, patent pending, abrasive machining manufacturing process for the formation of sub-millimetre holes in THGEMs, with the intended application in gaseous and dual-phase TPCs. Abrasive machining favours a non-ductile substrate such as glasses or ceramics. This innovative manufacturing process allows for unprecedented versatility in THGEM substrates, electrodes, and hole geometry and pattern. Consequently, THGEMs produced via abrasive machining can be tailored for specific properties: for example, high stiffness, low total thickness variation, radiopurity, moisture absorption/outgassing and/or carbonisation resistance. This paper specifically focuses on three glass substrate THGEMs (G-THGEMs) made from Schott Borofloat 33 and fused silica. Circular and hexagonal hole shapes are also investigated. The G-THGEM electrodes are made from indium tin oxide (ITO), with a resistivity of 150 Ω/Sq. All G-THGEMs were characterised in an optical (EMCCD) readout GArTPC and compared to a traditionally manufactured FR4 THGEM, with their charging and secondary scintillation (S2) light production behaviour analysed.

Experimental investigation into internal roundness of Inconel-718 thick cylinder using chemical assisted magnetic abrasive finishing process

With the progression of technology, demands of super alloys have been increased dramatically. One such super alloy is Inconel-718. Although, it is having an extensive application in aerospace industries, steam power plants and oil and gas refineries due to possession of some stringent properties like hot hardness, resistance to wear, high strength. Possession of these rigorous characteristics makes it hard to finish this alloy with the conventional finishing processes almost impossible. So the present work focuses on the predominant role in Industries by giving an edge on surface finishing with more precision and accuracy. To establish the process experimental setup and magnetic tool have been created for chemical assisted magnetic abrasive finishing process to inspect the enhancement in internal roundness of Inconel-718 cylinder. The processing unit has been installed on the lathe machine. Experiments have been performed on Inconel-718 cylinders with 5.7 mm in thickness, 155 mm in length. The experiments have been planned by means of Response surface methodology. Results of the experiments have been analysed with the help of analysis of variance. It has been found that with the operating parameters having specified values like duration of processing-80 mins, Pole work gap-4 mm, and abrasive weight percentage-30%, size of abrasive particle- 40 µm and concentration of Etchant- 700 gm/litre internal roundness improvement percentage for Inconel 718 cylinder is achieved as 42.86%.

Study on Finishing of Polychlorotrifluoroethylene Resin by Magnetic Abrasive Finishing Process with Renewable Abrasive Particles

Polychlorotrifluoroethylene material is used in industry as a material with excellent insulation, impact resistance and acid and alkali resistance. In this study, we used a magnetic abrasive finishing process with renewable abrasive particles to finish the surface of the polychlorotrifluoroethylene resin plate. Magnetic Abrasive Finishing (MAF) process is a technology that uses flexible magnetic brushes to improve the surface quality of materials. The performance of the magnetic brush is a key factor in surface finishing. In conventional MAF finishing, the number of abrasive particles in the magnetic brush is limited, and the position of the abrasive particles is relatively fixed, which will cause the cutting edge of the abrasive particles to gradually become dull and the finishing efficiency gradually decreases. This paper research the characteristics of the MAF process with renewable abrasive particles. This MAF process has a circulating system that uses a conveyor belt to renew abrasive particles. We use the polychlorotrifluoroethylene resin plate as the experimental processing object to conducted finishing experiment. And the surface roughness of the polychlorotrifluoroethylene resin plate is improved from 315 nm to 32 nm through this process.

Experimental investigation of µ-abrasive jet machining with dust collection mechanism

Micro abrasive jet machining process is an advanced machining process used for the production of micro holes, micro channels and machining of different type of brittle materials. It is a non contact type machining process, were highly pressurized air and abrasive particles are mixed using a mixing chamber and directed towards the work piece. The material is removed by means of mechanical erosion. During the machining time, there are lot of abrasive particles expelled out and it may cause environmental pollution. To avoid this problem an abrasive dust collector mechanism with liquid film is used in the current work. In this experiment the work piece is placed in the liquid chamber and three input process parameters such as mass flow rate, standoff distance, motor speed and there effects on the output responses such as material removal rate, radial overcut and area of frosted zone is discussed. The process parameters are optimized using Taguchi method and utility concept in Minitab statistical software.

Heuristic optimization techniques in abrasive water jet hole making – A case study

Evolutionary algorithms are commonly used for the purpose of modelling manufacturing processes as they provide results with a great amount of efficiency and accuracy. This article presents a comparison between the two of the most popular optimization techniques namely genetic algorithm and simulated annealing. These techniques have been compared step by step by applying to an abrasive water jet drilling process. The process is represented with the help of both the models and the methods/results are compared. Inputs considered for developing the model are water pressure, abrasive flow volume and standoff distance. The responses selected are overcut, circularity and drill rate. In both the optimization models four stages are reported. Each model is characterized by the change in weights of the factors and the results for the individual cases have been analyzed. The results show that the results obtained from both the techniques is very close but the time required for genetic algorithm is considerably less when compared to the simulated annealing procedure.

Optimal Selection of Backside Roughing Parameters of High-Value Components Using Abrasive Jet Processing

This paper mainly presents a set of new Sapphire Backside Roughing technology. Presently, the associated Sapphire Backside Roughing technology is still concentrated on chemical etching, as its yield rate and efficiency are often limited by lattice structures, and the derived chemical waste fluid after etching is most likely to cause ecological contamination. In this research, refined abrasive jet processing technology is adopted, and in the meantime, the Taguchi experiment design method is taken for detailed experimental planning. Through processing parameter conditions and abrasive selection and development, proper surface roughing and processing uniformity are obtained so as to improve the various weak points of the abovementioned traditional etching effectively. It is discovered that abrasive blasting processing technology is, respectively, combined with wax-coated #1000 SiC particles and wax-coated #800 Zirconium particles to process the sapphire substrate with initial surface roughness 0.8–0.9 μmRa from the experiment. A 1.1–1.2 μmRa surface roughness effect can be achieved about two minutes later. The experimental results show that the actual degree of sapphire substrate surface roughing obtained in the AJM process depends on the gas pressure, impact angle, wax-coated abrasives, and additives. The new Sapphire Backside Roughing technology has high flexibility, which not only meets the requirements for sapphire surface roughing specification but can also effectively reduce the sapphire substrate roughing time and related cost.

Investigation on the Finishing Characteristics of a Magnetic Abrasive Finishing Process with Magnetic Abrasive Slurry Circulation System

The magnetic abrasive finishing (MAF) process is an ultra-precision surface finishing technology. In order to further improve the finishing efficiency and continuity, a magnetic abrasive finishing process using the circulatory system to renew magnetic abrasive slurry was proposed. This study investigated the mechanism of the compound magnetic finishing fluid in the process using the conveyor belt as the carrier to complete the circulation and finishing through simulation and theoretical analysis. The influence of the different distribution states of the magnetic finishing fluid in the conveyor belt and the finishing area on the finishing characteristics is observed and analyzed, in addition to a series of experiments to explore the feasibility of finishing polychlorotrifluoroethylene resin plate through this process. Experimental results show that as the working gap decreases, the distribution width of compound magnetic finishing fluid on the conveyor belt becomes larger, and the distribution of the points of action on the workpiece in the finishing area is significantly different and the area increases, and obtains a higher finishing force and finishing efficiency. In this study, the surface roughness of polychlorotrifluoroethylene resin plate was improved from 274 nm Ra to 34 nm Ra within 15 min.

ФИНИШНАЯ АБРАЗИВНАЯ ОБРАБОТКА ТОНКОСТЕННЫХ ПЛАСТИН

The features of the final machining of thin-walled plates are given. The calculation scheme for the kinematic parameters of abrasive finishing of thin-walled easily deformable plates and the mathematical dependence for calculating the pressure on the lapping faceplates with the processed parts are determined. The aim of the work is to obtain an analytical dependence that establishes the relationship between the operating parameters and the conditions of the abrasive finishing process with the roughness of the working surface of the plates. The task, which the article is devoted to solve is theoretical and experimental studies of the influence of technological modes and conditions of abrasive finishing of plates with complex relative movement of parts and lapping on the roughness of the treated surfaces, as well as in the development of a methodology for determining rational modes and conditions of surface treatment of thin-walled plates. Theoretical research was carried out on the basis of the main provisions of mechanical engineering technology, grinding theory, theoretical mechanics, theory of elasticity and plasticity, probability theory and mathematical statistics. Experimental studies have been carried out according to standard methods in production and laboratory conditions using certified control and measuring equipment. The obtained data were processed using computer technology and presented in the form of empirical dependencies that are convenient for practical application.
 The originality of the work consists in obtaining mathematical dependencies for calculating the kinematic parameters and parameters of the contact interaction of abrasive particles with the treated surfaces of the plates, which allow determining the rational values of the ratio of the speeds of movement of the plates and lapping.

Analysis of the polymeric abrasive paste regeneration for abrasive flow machining

The influence of conditions and the sifting process efficiency of the worn-out polymeric abrasive paste containing silica (SiO2) and polymer chips remaining after the surface treatment were investigated. The abrasive paste regeneration process consisted of sifting the used paste through sievesof a vibrating screen, on which abrasive grains and polymer chips were recovered. The diameter of the sieve holes determined the size of the recovered abrasive grains and polymer chips, on the size of which the efficiency of the process depended. The lowest efficiency of the sifting process was obtained using a sieve with the holes diameter equal to the diameter of the grain and the polymer chips of thegiven fraction. The highest efficiency of the sifting process was obtained for a sieve with a diameter of 0.032 mm. The regenerated polymeric abrasive paste can be reused in the process of abrasive flow machining.

Influence of roughness on polar and dispersed components of surface free energy and wettability properties of copper and steel surfaces

The most urgent problems in meso-, micro- and nano-technological productions are controlling wetting of metals and alloys and liquid spreading over engineering surfaces after their hardware abrasive processing. Nowadays, there is a lack in theoretical basis and comprehensive experimental studies to predict the texture formation and change of the functional surface properties (including wetting) of metals and alloys after abrasive processing. In this study, based on the analysis of the three dimensional roughness parameters (amplitude, hybrid and feature) and elemental composition of the near-surface layer, the features of texture formation, changes in the surface free energy and wettability of copper and steel surfaces that are widely used in industry were established after their hardware abrasive processing. The use of abrasive material with an average grit size of up to 100 μm was found to significantly change the surface roughness. The abrasive processing significantly modifies the polar component in the surface free energy, while not influencing its dispersed component. The texture parameters allowing one to control both the growth and decrease of the polar component in the surface free energy were determined. It is shown that the abrasive processing directly influences the wettability properties and allows varying the contact angles in a sufficiently wide range of from 54.0° to 108.2° (for copper surfaces) and from 71.6° to 89.5° (for steel surfaces).

Технологические основы обработки полимеркомпозитных деталей гибким абразивным инструментом

There are presented investigation results of polymer-composite parts abrasion. The dependences for the definition of surface roughness at polymer-composite material hydro-abrasive cutting are shown. The results of theoretical and experimental investigations of hydro-abrasive cutting processes are presented. A procedure for their carrying out, tool and equipment used is described. The results of experimental investigations on polymer-composite parts preparation to splicing are shown. A procedure for designing a technological process of polymer-composite parts abrasion is offered.

Development of an Inner Finishing Method for Brass Cone Pipe via a Movable Manual Electromagnet in a Magnetic Abrasive Finishing Process

This paper describes the development of a movable manual electromagnet with an adjustable flux density to improve the inner surface smoothness of a cone pipe using a magnetic abrasive finishing process. This method is fabricated to reduce further the roughness of the internal surface of the conic shape, which was modeled as an electromagnet oscillating in the work zone with a ball roller. Statistically significant improvement in the process was achieved using unbounded magnetic abrasive, light oil, flux density, controlled feed rate, and constant rotational speed in the experiment. The ball transfer equipped on the top of the electromagnet pole plays an essential role in spinning over the outer cone pipe during the experiment and helps reduce friction while the workpiece fluctuates. Furthermore, the flux density can be changed to control the magnetic force and select the most acceptable option. In addition, a procedure for finishing has been designed for finishing a cone pipe, and we sought to understand how the flux density affects the material in removal exterior roughness. As a result, the flux density is clarified, and a higher flux density achieves excellent removal of surface roughness of the inner deformed pipe from 1.68 μm to 0.39 μm within 24 min.