Beruflich Dokumente
Kultur Dokumente
12th14th, 2014,
IIT Guwahati, Assam, India
Abstract
The emergence of Abrasive Flow Finishing/Machining (AFFM) as an advanced fine finishing process
is attributed towards the need for relaxation of tool limitations, relative motion of work piece with
respect to tool and precise finishing of complex geometries and internal passages in components.
Herein, the abrasive laden polymer media conforms to the work piece geometry overcoming shape
limitation inherent in conventional finishing processes. The paper outlines the various functionalities
of the AFFM system developed and the experimentation carried out for finishing and deburring of
modular head of a hip joint, extrusion die and shuttle valve used in bio-medical, aerospace and
pharmaceutical industries respectively are discussed. Surface characterization of the finished
components using optimized process parameters are discussed in detail. The reported results signify
the versatility and deterministic aspect of the developed AFFM machine for surface finishing of
ferrous and non-ferrous components.
recorded after AFFM at two different extrusion measurement was done using a Veeco NT9100
pressures. Lower working pressures were Optical profiler which works on the principle of
recommended for achieving better surface finish light interferometry for analysis of surface
which was attributed to the better conformity of the topography and roughness of the finished
polymer abrasive mixture with the component. component.
Balashanmugam et al (2013).
The internal features of a transmission
The material composition of the shuttle valve component can be blended and surface smoothened
used in the present study was a Fe - 15 Cr - 5 Ni by AFFM to allow easier sliding of the two
precipitation hardened stainless steel designated as components in a die assembly. In the present work
AMS 5659 (15-5PH) / ASTM A564. It is one a die mould (od - 30.3mm; id - 15.4mm;
among the primary components in brakes, landing height - 22.5mm) made of die steel of hardness
gear extension, flap extension and canopy release 50HRC was taken up for finishing. The ability of
mechanisms during emergency in an aircraft. Pre- the abrasive laden polymer media to conform to the
finishing operations of the shuttle valve (figure 1a) complex shape of the component aided in finishing
demanded the removal of hard-to-reach burrs at of processing dies. The initial Ra values recorded at
internal cross-hole intersections (figure 1b). three different positions are as shown in figure 2a.
AFFM was operated in the two- way flow
configuration at a hydraulic pressure of 100 bar
using consecutively two media of different grit
sizes of abrasives mixed with the dilatants polymer.
The total cycle time taken for finishing of the die
mould to the required Ra value of 0.1m from an
initial value of 2m was approximately 150
minutes. The die assembly components after AFM
are shown in figures 2 b and c which are indicative
of the quality of surface finish attained.
a b
Figure 2 Graphical representation of the Surface roughness parameters recorded before and after
intermediate and final AFF
Acknowledgement
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5th International & 26th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12th14th, 2014,
IIT Guwahati, Assam, India
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