Abrasive flow machining

A presentation on Abrasive Flow Machining with process and working

1. Abrasive Flow Machining Mohit Ostwal Assistant Professor Department of Mechanical Engineering Jodhpur Institute of Engineering and Technology, Co-ed, Jodhpur 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 1

2. Content What is AFM? Need of AFM Abrasive Material Mechanism of AFM Classification One Way Two Way Orbital Process input parameters Application areas 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 2

3. Abrasive Flow Machining It is basically used as a deburring process. Developed in 1960 by Extrude Hone Cooperation. AFM can Polish and deburr parts internally Polish through holes Polish intersecting holes Calibrate fuel injection nozzles to a specific flow rates Uses abrasive grains mixed in a putty (a form of cement) like matrix which abrades the surface/burrs from the specific area of the material. 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 3

4. NEED Smooth surfaces – Aerospace and precision components High flow rates – Fluid dynamics and nozzles Torque and fuel economy – Fuel nozzles and engine components Eliminate the imperfections – Medical field 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 4

5. Abrasive Material Abrasives Aluminum oxide S ilicon carbide Boron carbide Diamond Mixed in Polymeric medium Viscoelastic polymer- shows change in viscosity when under pressure 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 5

6. Mechanism Of AFM 1. Initially the material is ploughed by the fine abrasives which come in contact with the work material as the rub over the metal surface with high pressure. 2. The material flow occurs in the direction of the motion of abrasive particles as well as in lateral direction, resulting into the formation of the leaps. 3. The further flow of abrasive particles causes continued work hardening which results in embattlement and fragmentation of the lips into micro chips. 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 6

7. Mechanism of AFM 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 7

8. Components of AFM Machine Tooling Workpiece Fixture plate Fixtures Pumping device Abrasive materials/medium 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 8

9. Classification of AFM One way Two Way Orbital 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 9

10. One-way AFM One-way flow AFM processing pushes abrasive media through the work piece in only one direction, allowing the media to exit freely from the part. 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 10

11. Advantages of One-way AFM Faster cycle processing Easy clean-up Media temperature control generally not required Able to process larger parts Simpler tooling and part change-over Accurately replicates air or liquids natural flow Does not encapsulate work-part in media 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 11

12. Two-way AFM Most widely used among the three. The typical two-way flow AFM process uses two vertically opposed cylinders to extrude an abrasive media back and forth through or around passages formed by the workpiece and tooling. Abrasive action occurs wherever the media enters and passes through the most restrictive passages 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 12

13. Two-way AFM(contd.) 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 13

14. Two-way AFM(contd.) 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 14

15. Advantages of Two-way AFM Excellent process control Can finish both ID and OD of component Good control of radius generation Fully automated system capabilities Faster setup & quick-change tooling Faster change-over of media 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 15

16. Orbital AFM Surface and edge finishing are achieved by rapid , low-amplitude, oscillations of the work piece relative to a self-forming elastic plastic abrasive polishing tool. The tool is a pad or layer of abrasive-laden elastic plastic medium (similar to that used in two way abrasive flow finishing ), but typically higher in viscosity and more in elastic . 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 16

17. Orbital AFM(contd.) Before starting of finishing After starting of finishing 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 17

18. AFM process parameters Machine Abrasive Workpiece Extrusion pressure Flow Volume Media flow speed Number of Cycles Medium viscosity Abrasive Concentration Abrasive type & size Restricting passage flow and area Ductile/Brittle 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 18

19. AFM process parameters Abrasive Based Abrasive grain size used in AFM varies from 500 grit (tiny hole) to 8 grit (stock removal and stocking) Large abrasives- cut faster Small abrasives – better surface finish as well as they can reach narrow and complex surfaces easily. Machine Based Pressure - 0.7 Mpa to 22 Mpa (100 psi to 3200 psi) 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 19

20. Capabilities of AFM process Surface finish in the range of 28 to 280 μ m. Hole of 0.2 mm can be made. Dimensional tolerances achievable upto ± 0.005mm. Can reduce surface roughness by 75 to 90% on cast, machined or EDM sufaces . 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 20

21. Application Aerospace industry Improved surface quality Enhanced cycle fatigue strength Optimized combustion and hydraulics Increased airflow Extended component life 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 21

22. Application 2. Automotive industry Enhanced uniformity and surface quality of finished components Increased engine performance Increased flow velocity and volume Improved fuel economy and reduced emissions Extended work piece life by reducing wear and stress surfaces Grains in same direction will increase the flow rate 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 22

23. Application 3 . Dies and mold industry Reduced production costs Increased production throughput Enhanced surface uniformity, finish and cleanliness Improved die performance and extend life of dies and molds 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 23

24. Application 4 . Medical industry (Medical implants) Eliminate the surface imperfections where dangerous contaminates can reside Improved functionality, durability and reliability of medical components Enhanced uniformity and cleanliness of surfaces , Extended component life 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 24

25. 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 25

26. THANK YOU 2/12/2016 Mohit Ostwal, Asst. Prof., ME, JIET-Co-ed, Jodhpur 26