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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.
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
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
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%).
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%).
Acknowledgements
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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