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Robotics and Computer Integrated Manufacturing 15 (1999) 403}412

Simulation of surface generated in abrasive #ow machining process


Rajendra Kumar Jain1, Vijay Kumar Jain*
Mechanical Engineering Department, Indian Institute of Technology, Kanpur 208 016, India

Abstract

For the control of abrasive #ow machining (AFM) process, it is important to understand the mechanics of generation of its surface
pro"le. This paper describes the analysis and simulation of pro"le of "nished surface and material removal by the interaction of
abrasive grains with workpiece. The abrasive grains are randomly distributed in media depending upon their percentage concentra-
tion and mesh size. The results predicted from simulation and obtained from response surface analysis (or experiments) are compared
to explain the relative importance of AFM parameters. The generated surface pro"le and material removal are the function of number
of cycles, percentage concentration and mesh size of abrasives, reduction ratio and extrusion pressure applied. ( 1999 Elsevier
Science Ltd. All rights reserved.

Keywords: AFM; Simulation; Surface roughness; Material removal; Parametric analysis

Nomenclature r media cylinder radius, m


#
r workpiece radius, m
8
b side of a square cross section, m R surface roughness, lm
!
C percentage concentration of abrasives by R reduction ratio
%
weight t depth of indentation, m
d grain diameter, m < volume of abrasives, m3
' !
H hardness of workpiece material, MPa x, y , z random variables de"ning grain position
8
l length of workpiece, m along axial, transverse and vertical
8
M mesh size directions
N number of AFM cycles o density of abrasives, kg/m3
!
p extrusion pressure, MPa o density of carrier, kg/m3
#
p normal pressure acting on the grains, MPa o density of media, kg/m3
/ .
r grain radius, m p standard deviation of the grain radius
' 3

1. Introduction this process include "nishing of components in aero-


space, automotive, dies, chemical processing and medical
Abrasive #ow machining (AFM) is a non-traditional industries. Materials from soft aluminum to tough nickel
"nishing process that is used to deburr, polish, radiusing, alloys, ceramics and carbides have been successfully
remove recast layer and to produce compressive residual micro machined by this process [1]. AFM process pro-
stresses, even in di$cult to reach areas. Applications of vides a high level of surface "nish and close geometric
tolerances with economically acceptable rate of surface
generation for a wide range of industrial components.
The ability of media in AFM process to "nish di$cult to
* Corresponding author.
E-mail address: vkjain@iitk.ac.in (V.K. Jain) reach areas, to follow complex contours and to simulta-
1 On leave from Madhav Institute of Technology and Science, neously work on multiple edges and surfaces, makes it
Gwalior 474 005, India. more versatile than other "nishing processes.

0736-5845/99/$ - see front matter ( 1999 Elsevier Science Ltd. All rights reserved.
PII: S 0 7 3 6 - 5 8 4 5 ( 9 9 ) 0 0 0 4 6 - 0
404 R.K. Jain, V.K. Jain / Robotics and Computer Integrated Manufacturing 15 (1999) 403}412

workpiece. By simulating these individual events, it is


possible to predict the characteristics of surface gener-
ated in AFM.
In case of grinding, there have been many attempts
in the past to model the surface generated using statist-
ical approach [2]. Yoshikawa and Sata [3] simulated
the grinding process by the Monte Carlo method.
Random numbers were used to give the coordinates
of the position of a grain on the grinding wheel. By
this method, the distribution of the grains spacings and
of the undeformed chip geometry, together with the
generated surface pro"le are obtainable from the struc-
ture of the grinding wheel which has random character.
The assumption of the grains existing independent
of each other on the wheel surface is the major draw-
back of this model. A grinding model was postulated by
Law and Wu [4], in terms of grains distribution on the
abrasive wheel and kinematic grinding conditions.
Fig. 1. Schematic diagram of AFM process.
Transverse workpiece pro"les have been conjectured as
sample realizations of the stochastic grinding process.
Hamed et al. [5] applied an approach to generate ran-
AFM removes small quantity of material by #owing dom surfaces by computer simulation which involves the
a semisolid abrasive-laden compound called &media' use of a series of &unit events' to produce a surface pro"le.
(abrasive particles uniformly suspended in viscous chem- The work con"rmed that the random engineering surfa-
ical compound) through or across the surfaces of the ces can be described statistically by a pro"le having
workpiece to be "nished. Two vertically opposed cylin- ordinate heights with a Gaussian distribution together
ders extrude media back and forth through passages with a form of exponential autocorrelation function.
formed by the workpiece and tooling (Fig. 1). The ma- Bhateja [6] evolved a hypothesis that the ground surface
chining action compares to a grinding or lapping opera- texture is complementary to the envelope of a large
tion as the media gently and uniformly abrades the number of active transverse wheel pro"les that traverse
surfaces and/or edges. The media acts as a &self-deform- the grinding zone. Based on this approach, the relation-
able stone' having protruding abrasive particles acting as ship between the roughness of the wheel and the work-
cutting tools. The media is composed of semisolid carrier piece could be established. Classical two-body abrasion
(polyborosilixane) and abrasive grains. theories have been applied in a statistical simulation
Both theoretical and empirical studies of AFM are model by Sta!an et al. [7]. A unique feature of the model
greatly hampered by the inherent random nature and is that the abrasive simulation is performed on a surface
multiplicity of variables. Further, not much information of realistic topography, developed during the simulation
is available in the literature which deals with simulation process.
of surface generation and material removal in AFM The approaches discussed above, to model surface
process. Simulation techniques can help in understand- generation can be applied to abrasive #ow machining
ing the mechanics of the AFM process as well as in process with certain modi"cations depending upon the
predicting the e!ects of various process parameters on AFM conditions. As the distribution of grain cutting
the responses. edges in the media is random and grains which contrib-
The abrasive #ow machining process can be described ute to generate a measurable pro"le on the workpiece
as random removal of material by individual abrasive are numerous, it is impossible to describe the necessary
grains in the form of microchips. The shape of removed con"guration of media surface in a deterministic way.
material is determined by the kinematics of the AFM On the other hand, it is possible to obtain a complete
process and the shape of abrasive grain. It is easier to pro"le of workpiece surface generated by motion of
calculate the shape of a cut groove from the relative the grains, by simulation. The surface generated in
motion between the workpiece material and the grain AFM is the cumulative outcome of numerous abras-
under consideration. However, it is di$cult to estimate ive}workpiece interaction events. By simulating these
the roughness of the machined surface. This di$culty individual events, it is hence possible to predict the
is due to the complicated and random distribution characteristics of machined surface. Implementation
of grains in the media. Abrasive #ow machining is of the same, requires information on the topography
viewed as a stochastic process whose events are gener- of the AFM media and the kinematics of the AFM
ated by the interactions between the abrasive grains and process.
R.K. Jain, V.K. Jain / Robotics and Computer Integrated Manufacturing 15 (1999) 403}412 405

The present paper describes a versatile simulation using Eq. (1).


model which generates and statistically evaluates the
r #r (M #M )
interaction between spherical abrasives and a realistic r "! " "3.81 ! " . (2)
surface. The simulation enables prediction of the rough- '. 2 M M
! "
ness of the machined surface and material removal with Since, the range of normally distributed random vari-
reference to the abrasive grit size, percentage concentra- ables, in general, is six times the standard deviation, the
tion, etc. standard deviation of the grain radius p is evaluated as
3
(M !M )
p "1.27 ! " . (3)
2. Simulation of surface generation 3 M M
! "
For AFM media with percentage concentration of
The method applied to explore the nature of the gener- abrasives by weight as C, the total volume of abrasive
ated pro"le is by simulation of the mechanics of AFM grains < in the total volume of media < is given by
process. The model used for material removal in AFM ! .
process is restricted to pure micro-cutting without mater- Co <
< " . ., (4)
ial displacement. All considerations are geometrical in ! 100o
!
nature. During AFM process, media is passed across the
where, density of abrasive media o in terms of abrasive
workpiece surface. AFM is considered to be a scratching .
density o and carrier density o is given by the relation
action performed by abrasive grains in the media. The ! #
force applied to the media will cause an active grain to 100o o
o " ! # . (5)
indent in the workpiece surface. The grain produces . [Co #(100!C)o ]
a groove on workpiece surface, and groove cross section # !
Length of media l passed through workpiece in one
corresponds to the pro"le of the grain. As the grain is .
translated horizontally, it removes material from the stroke,
workpiece surface. r2l
l " # 4 "l /(1!R ), (6)
The simulation of surface generation in AFM is carried . r2 4 %
out based upon the following assumptions: 8
where, l is length of stroke and R is reduction ratio. In
4 %
1. The path traced by an individual grain is a straight terms of media cylinder radius (r ) and workpiece radius
#
line. (r ), it is given by R "1!(r2 /r2). Reduction ratio ex-
8 % 8 #
2. The material is removed in the form of chips through presses the reduction in cross sectional area of #ow of
plastic deformations without the side pile up, when- media. It is de"ned as the di!erence between cross-sec-
ever grain workpiece interference occurs. tional area of media cylinder and workpiece, divided by
3. Abrasive grain is approximated by a sphere. Experi- the cross-sectional area of media cylinder.
mental observations of abrasive particles also show The depth of indentation of abrasives in the workpiece
that they are generally round in shape, and are not is very small. To simplify the analysis, total periphery of
composed of acute cutting edges [8]. circular cross section is converted to equivalent periph-
4. In the formation of particles, a large number of chance ery of square cross section, keeping total length of media
factors are at work. This leads to the emergence passed through the workpiece as constant.
of a normal distribution of particle size, which has Side of square cross section,
been observed to hold for narrow distribution [2].
pr
Hence, the distribution of abrasive radii is assumed to b" 8 . (7)
be normal, and symmetric about the mean grain 2
radius. A square cross section of side b (Fig. 2) and length l of
.
the AFM media is considered for simulation. The total
Since each nominal grit size includes a range of abras-
volume of abrasive grains (< ) is related to the volume of
ive particle size, two grit numbers M and M are used to !
! " media (< "b2l ) as
denote the abrasive size. M refers to the sieve that would . .
!
let the abrasive grains pass through and M to the sieve
" Cb2l o
<" . .
that would detain most of them. The grit radius r is
' ! 100o
related to the sieve number [9] as !
Cb2l o
" . # . (8)
r (mm)"7.62 M~1. (1) Co #(100!C)o
' # !
As the distribution of abrasive radius is assumed The "rst step in the simulation is to generate &Na',
to be normal and symmetric about the mean grain normally distributed random numbers with mean radius
radius, the mean grain radius (r ) is given as follows r and standard deviation p which correspond to the
'. '. 3
406 R.K. Jain, V.K. Jain / Robotics and Computer Integrated Manufacturing 15 (1999) 403}412

two adjacent grains is equal to or more than the sum of


their radii.
[(x !x )2#(y !y )2#(z !z )2]1@2*(r #r ),
i j i j i j i j
j"1 to (i!1). (11)
The pro"le of the workpiece surface can be displayed
in the form of a two-dimensional cross-section perpen-
dicular to the grooving direction. In the manufacturing
processes involving the random removal of material, the
roughness is e!ectively produced by many independent
particles hits. The amplitude distribution of the
roughness waveform can be justi"ably expected to be
Gaussian, no matter how much of the individual hits
have a!ected the surface pro"le [4]. The original pro"le
of the workpiece is taken to be Gaussian, represented in
digital form and coordinates (x@, z@) of the pro"le are
stored at 0.1 lm spatial resolution.
The centers of the abrasive grains (x , z ) are de"ned
i i
with respect to the coordinate system "xed to the
workpiece. Active grains are only those grains which
actually take part in the material removal. During the
simulation process, if the active grain interacts with
the workpiece pro"le at the appropriate location, then
Fig. 2. (a) Schematic representation of simulated AFM media. a hit is recorded. The indenting grain would have some of
(b) Cross-sectional representation of workpiece surface and abrasive
media.
its z coordinates below the corresponding z coordinates
of work surface pro"le (Fig. 3). These grains can be
identi"ed by segregating the grains which satisfy the
grain radius r such that following condition:
'
z@!(z !r )*0.0. (12)
4 N! i i
+ r3+< , (9)
3 'i ! The machining process is simulated by comparing the
i/1 coordinates of a grain with the relevant workpiece sur-
where, r is the radius of the ith grain. face points. The coordinates of the cutting surface of
'i
For a spherical grain of diameter d , the maximum a grain are generated by solving the equation of a circle
'
depth of indentation t of a grain in workpiece material for discrete values of x. An active grain such as G1 of
can be given by [10] radius r (Fig. 3) can modify the work pro"le only within
i
the interval (x !r ) to (x #r ). It is assumed that the
i i i i
S
d d p cross-sectional shape of the groove formed by the sliding
t" ' ! ' 1! / ,
2 2 H (10) abrasives on the workpiece surface con"rms to the circu-
8
lar pro"le of the abrasive i.e., material removal is by ideal
where, p is normal pressure acting on the grain and ductile microcutting with no pile-up of material towards
/
H is hardness of workpiece material. the sides of the groove.
8
The distribution of grains in the media is represented
by giving their coordinates (x, y, z), which represent the
position of a grain in axial, transverse and perpendicular
to the surface directions. Grains are randomly positioned
in the AFM media so that x, y, and z generally have
a uniform distribution. Thus, the position of the center of
each of N grains with respect to the surface is decided by
!
a random number generator.
Only those grains which do not overlap are con-
sidered. For this purpose, the grains are assumed to
occupy a region of in#uence equivalent to nominal
grain diameter. Generation of the coordinates of the ith
grain is subject to the condition, that distance between Fig. 3. Schematic interaction of an abrasive with workpiece surface.
R.K. Jain, V.K. Jain / Robotics and Computer Integrated Manufacturing 15 (1999) 403}412 407

Material removal in AFM process is simulated by For studying the characteristics of the machined sur-
successive abrasive grains grooving in the workpiece. The face, a projected pro"le length of 12 mm was considered
height of the pro"le at that location is then modi"ed to at a resolution of 1 lm. For sampling length, the mean
correspond to this interaction. The pro"le of the work line was computed such as the area of the solid above
surface as each active grain slides over it, is modi"ed by the line is equal to the area of the void below it. The
transforming the coordinates of the interfering pro"le roughness parameter Ra is the average height from a
of individual active grain to the workpiece, based on mean line of all ordinates of the surface, and is calculated
geometrical considerations alone. The computer then as follows:
calculates the successive new heights of the work pro"le

P
from the tip of the grain, thus generating new work 1 L
Ra" Dz(x)D dx, (13)
surface pro"les. After each grooving event, the groove ¸
0
width and volume of material removal are calculated and
stored. A simulated machined surface and volume of where, z(x) is the height of the pro"le from the mean line
material removed are obtained after all the active grains and ¸ is the sampling length used to compute the average
present in the media have participated during each AFM roughness of the pro"le. Since the initial surface rough-
stroke. This process of simulation starting from genera- ness of all the workpieces "nished during experimenta-
tion of random numbers to modi"cation of workpiece tion was not exactly same, hence change in surface
surface pro"le is continued until the required number of roughness of the machined surface has been plotted for
cycles of AFM process are completed. The #ow chart of comparison purposes in place of actual surface roughness
AFM simulation is shown in Fig. 4. values obtained after AFM.

3. Experimentation

AFM experiments were carried out on the AFM


machine to study the e!ects of various process para-
meters mainly, media pressure (x ), number of cycles (x ),
1 2
reduction ratio (x ), and percentage concentration of
3
abrasives (x ), on AFM performance. Internal surface
4
of mild steel workpieces with circular cross section is
"nished using abrasive media (SiC abrasives mixed with
polyborosilixane carrier). Experiments are designed
using central composite rotatable design to get the useful
inferences by performing minimum number of experi-
ments. A second-order rotatable design is used for the
response surface analysis (RSA). The following second-
order response surface equations are obtained from RSA
to predict material removal (MR) and change in surface
roughness (*R ).
!
MR"21.714#4.358x #5.350x #6.658x
1 2 3
#4.025x !0.703x2 !0.928x2
4 1 2
#1.808x2 #0.158x2 #0.262x x
3 4 1 2
#0.487x x #0.862x x #0.900x x
1 3 1 4 2 3
#0.375x x #2.750x x , (14)
2 4 3 4
*R "0.617#0.101x #0.119x #0.107x
! 1 2 3
#0.067x !0.009x2 !0.006x2
4 1 2
#0.029x2 #0.006x2 #0.023x x !0.0006x x
3 4 1 2 1 3
#0.0018x x #0.0068x x
1 4 2 3
Fig. 4. Flow chart of AFM simulation. #0.0093x x !0.0118x x . (15)
2 4 3 4
408 R.K. Jain, V.K. Jain / Robotics and Computer Integrated Manufacturing 15 (1999) 403}412

Fig. 5. Comparison of RSA and experimental variation of material


removal with extrusion pressure (C"66%, Re"0.905, N"15).

Responses have been calculated using Eqs. (14) and


(15) to study the e!ects of various parameters on material
removal and change in surface roughness. In the follow-
ing sections, the results obtained using Eqs. (14) and (15) Fig. 6. Initial surface pro"le and surface pro"le obtained after simula-
tion (p"50 bar, M"50}60, Re"0.905, N"15, C"66%).
are termed as response surface analysis (RSA) results.
Figure 5 shows that the experimental points are close to
those predicted by RSA. Hence, RSA results can be
considered as representatives of experimental results.

4. Results and discussion

The conditions under which simulation has been done


are given in Appendix A. The surface pro"le perpendicu-
lar to AFM direction obtained after simulation is
illustrated in Fig. 6. The sampling length is 1 mm with
coordinates at 1 lm resolution. This pro"le resembles to
actual surface pro"le obtained from AFM experiments.
Real roughness of actual AFM'd surface is distorted from
such an ideal pro"le due to various causes, some of which
are probabilistic and others systematic in nature. Consid-
erations of real shape of grains, wear of grains, e!ect of
elasticity, pile up of material and actual initial surface Fig. 7. Variation of material removal with percentage concentration of
pro"le of the work will provide more realistic results in abrasives (p"50 bar, Re"0.905, N"15).
the simulation. Thus, the comparison of real surfaces to
simulated ones provides us with information about real
system.
correlation between experimental and simulation results.
4.1. Material removal Also, the di!erence between the RSA results and results
due to simulation may be due to error in measurement of
Figure 7 shows the e!ect of concentration of abrasives active grains density at higher values of abrasive concen-
by weight on material removal obtained by both ex- tration. Also generally, the measured value and stochasti-
periments (RSA) and simulation. As the percentage cally determined value of active grains density are higher
concentration of abrasives in media increases material than the actual active grains density e!ective during
removal also increases, because higher concentration of AFM. Hence, the predicted values (by simulation) of
abrasives results in higher number of active grains material removal at higher concentration are generally
and hence higher material removal. There is a good higher than the RSA data.
R.K. Jain, V.K. Jain / Robotics and Computer Integrated Manufacturing 15 (1999) 403}412 409

Fig. 8. Simulated variation of material removal with mesh size of grains Fig. 10. Variation of material removal with reduction ratio (p"50 bar,
(p"50 bar, C"66%, Re"0.905, N"15). N"15, C"66%).

Fig. 11. Variation of material removal with number of cycles (p"50


Fig. 9. Variation of material removal with extrusion pressure bar, Re"0.905, C"66%).
(Re"0.905, N"15, C"66%).

Figure 8 shows the simulated e!ect of mesh size Material removal also increases with increase in reduc-
on material removal for mild steel workpieces. From tion ratio (Fig. 10), due to increase in slug length of
the "gure, it is evident that as the mesh size increases, the media passed per stroke. This permits more number
material removal also increases. The reason for increase of grains to come in contact with the workpiece surface
of material removal is that with increase in mesh size, in a cycle. At higher reduction ratio, the normal stresses
area of the indented groove and depth of indentation acting on the workpiece surface are higher (or higher
decrease but the total number of interferences between depth of indentation), leading to higher material re-
grains and workpiece increases due to increase in active moval. At lower value of reduction ratio, the simulated
grains density. The overall e!ect is an increase in material material removal can be seen to be in good agreement
removal with increase in abrasive mesh size. with the RSA results. At higher end of reduction ratio
It is found that material removal increases with there is an increasing di!erence between the two results.
increase in extrusion pressure (Fig. 9). Approximately, Material removal value increases with the number of
the same trend is seen in case of RSA results also. But at cycles (Fig. 11), and also the di!erence between the
higher pressure, number of abrasive grains taking part in simulated and RSA results increases with increase in
actual cutting may be less due to rolling of grains at number of cycles. Simulated material removal in a speci-
higher velocity. Hence, actual material removal (i.e., RSA "ed number of cycles decreases with increase in hardness
results) will be less than simulated one which can be seen of workpiece material due to decrease in depth of inden-
from Fig. 9 also. tation (Fig. 12).
410 R.K. Jain, V.K. Jain / Robotics and Computer Integrated Manufacturing 15 (1999) 403}412

Fig. 12. Simulated variation of material removal with hardness of Fig. 14. Simulated variation of change in surface roughness with aver-
workpiece material (p"50 bar, C"66%, N"15, Re"0.905). age mesh size of grains (p"50 bar, C"66%, Re"0.905, N"15).

Fig. 13. Variation of change in surface roughness with percentage Fig. 15. Variation of change in surface roughness with extrusion pres-
concentration of abrasives (p"50 bar, N"15, Re"0.905). sure (Re"0.905, N"15, C"66%).

4.2. Surface roughness

The e!ect of percentage concentration of abrasives on


the change in surface roughness indicates the increase of
change in surface roughness with increase in percentage
concentration of abrasives (Fig. 13). With higher concen-
tration of abrasives, the number of abrasives taking part
in machining is more, and hence surface roughness ob-
tained for a speci"ed number of cycles will be better.
Change in surface roughness value is higher with de-
crease in average mesh size (Fig. 14).
Figure 15 exhibits the role of extrusion pressure on
change in surface roughness value obtained after the
speci"ed number of machining cycles. It is observed that
Fig. 16. Variation of change in surface roughness with number of cycles
*R value increases with increase in extrusion pressure.
! (p"50 bar, Re"0.905, C"66%).
Figure 15 also presents a comparison of the change in
surface roughness as a function of extrusion pressure,
computed by simulation and due to RSA. The simulated (Fig. 16) and reduction ratio (Fig. 17). Comparison of
results have almost the same trend as that of the RSA results indicates that results due to simulation and RSA
results. *R value also increases with number of cycles are in a good agreement as far as lower numbers of cycles
!
R.K. Jain, V.K. Jain / Robotics and Computer Integrated Manufacturing 15 (1999) 403}412 411

surface obtainable in AFM. The simulation enables the


prediction of surface roughness and material removal
with reference to percentage concentration and mesh size
of abrasives, extrusion pressure, number of cycles and
reduction ratio. The active number of abrasive grains per
unit volume of media #ow increases with percentage
concentration of abrasives and reduction ratio, hence
higher material removal and change in surface roughness
is achieved. Extrusion pressure, grain mesh size and
hardness of workpiece a!ect the depth of indentation of
a grain in workpiece material. The signi"cance of these
parameters on "nal surface pro"le is discussed with refer-
ence to AFM process. Change in surface roughness value
and material removal increase with extrusion pressure,
Fig. 17. Variation of change in surface roughness with reduction ratio number of cycles, reduction ratio and percentage concen-
(p"50 bar, N"15, C"66%). tration of abrasives.

Acknowledgements

Authors acknowledge the "nancial support pro-


vided by the Department of Science and Technology,
Govt. of India, New Delhi, and Widia (India) Ltd,
Bangalore for the project entitled `Abrasive #ow ma-
chining processa.

Appendix 1. Numerical values of conditions used


in the simulation

Fig. 18. Simulated variation of change in surface roughness with hard- workpiece material"mild steel (0.25%C)
ness of workpiece material (p"50 bar, C"66%, N"15, Re"0.905).
hardness of workpiece material"2177.80 N/mm2
abrasive used"silicon carbide
mesh size of abrasives"50}60
length of workpiece"38.5 mm
are concerned. At higher value of number of cycles, diameter of media cylinder"87.5 mm
di!erence between RSA results and results obtained from stroke length"80 mm
simulation increases. In actual practice, there may be density of SiC abrasives"3220 kg/m3
more rolling of grains than sliding with reduction in initial surface roughness of workpiece"2.25 lm
surface roughness value at higher number of cycles. As
a result, there is less change in surface roughness in actual
AFM at higher number of cycles as compared to References
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