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Zeitschriftenartikel zum Thema „HELICAL ABRASIVE FLOW“

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Veröffentlicht am 11. September 2023

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1

Wang, A. Cheng, Kuan Yu Chen, Ken Chuan Cheng und H. H. Chiu. „Elucidating the Effects of Helical Passageways in Abrasive Flow Machining“. Advanced Materials Research 264-265 (Juni 2011): 1862–67. http://dx.doi.org/10.4028/www.scientific.net/amr.264-265.1862.

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Conventional AFM have difficulty achieving uniform roughness of an axial distribution in circular hole polishing due to limited unitary axial motion of abrasive media. Therefore, this work develops mechanism designs for different passageways to obtain multiple flowing paths of an abrasive medium, whose flowing behavior enhances polishing effectiveness by increasing the abrasive surface area and radial shear forces. The motion of the abrasive medium is studied by utilizing the design of the mold cores, which mold shapes include the circular passageway and helical passageway. The optimum design of the different passageways is then verified using CFD-ACE+ numerical software. Analytical results indicate that the optimum design is the mechanism with a passageway of six helices. Furthermore, surface roughness measurements demonstrate the increase in uniformity and the roughness improvement rate (RIR). Experimental results for surface roughness indicate that roughness deviation of six helices passageway of approximately 0.1001 m Ra is significantly better than those on a circular passageway of around 0.1760 m Ra. Additionally, the six helices passageway is also superior to circular passageway in reducing roughness improvement rate (RIR) by roughly 85% compared with RIR 75% for the circular passageway.

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2

Xu, Yong Chao, Ke Hua Zhang, Shuang Lu und Zhi Qiang Liu. „Experimental Investigations into Abrasive Flow Machining of Helical Gear“. Key Engineering Materials 546 (März 2013): 65–69. http://dx.doi.org/10.4028/www.scientific.net/kem.546.65.

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Abstract. Abrasive flow machining (AFM) is an effective method that uses the flow of a pressurized abrasive media for removing workpiece material. It is used to deburring, polishing or radiusing, etc. In this paper, the effect that AFM process on the surface of the helical gear is investigated. Then, the distribution of the velocities, shear rates and shear forces of the abrasive flow on the helical gear surface is obtained by CFD module of the COMSOL Multiphysics software. The simulation results show that the abrasive grains near the addendum, tooth surface and tooth root can be subjected to corresponding shear stress. Experimental results indicated that the surface roughness Ra of the left tooth surface, right tooth surface and addendum before processing 1.429um, 1.108um and 2.732um dropped after processing 0.228um, 0.216um and 1.754um. All burrs at the intersection between tooth surface and end surface has been cleared, the surface quality of the helical gear has been improved. Therefore, AFM method can improve the surface quality of the helical gear effectively.

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3

Wang, A. Cheng, Ken Chuan Cheng, Kuan Yu Chen und Yan Cherng Lin. „Finishing Performance of the Abrasive Flow Machining in Complex Holes by Using Helical Cores“. Key Engineering Materials 831 (Februar 2020): 52–56. http://dx.doi.org/10.4028/www.scientific.net/kem.831.52.

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Since abrasive gels with single direction motion are very difficulty to achieve the smooth surfaces in the complex holes finishing during abrasive flow machining (AFM), therefore, the helical cores were proposed here to create the multiple motions of abrasive gels to get the even surface of the complex holes in AFM. The results showed that helical core with 5 spiral grooves and narrow gap between the core tip and the hole could obtain the even surface and fine surface roughness after AMF.

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4

Cheng, Ken Chuan, Kuan Yu Chen, A. Cheng Wang und Yan Cherng Lin. „Study the Rheological Properties of Abrasive Gel with Various Passageways in Abrasive Flow Machining“. Advanced Materials Research 126-128 (August 2010): 447–56. http://dx.doi.org/10.4028/www.scientific.net/amr.126-128.447.

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Abrasive flow machining (AFM) is a simple and efficient method to remove recasting layers making by wire electrical discharge machining (WEDM). However, conventional AFM methods have difficulty achieving uniform roughness of an axial distribution in circular hole polishing due to limited unitary axial motion of abrasive media. Therefore, this work develops mechanism designs for different passageways to obtain multiple flowing paths of abrasive medium, whose flowing behavior enhances polishing effectiveness by increasing the abrasive surface area and radial shear forces. The motion of the abrasive medium is studied by utilizing different mold cores, which mold shapes include the circular, hollow and helical passageway. The optimum design of the passageways is then verified using CFD-ACE+ software, numerical results indicate that passageway with six helices performed better in the uniform surface roughness than others’ do. Experimental results show that roughness deviation of six helices passageway of approximately 0.100 m Ra is significantly better than those on a circular passageway of around 0.1760 m Ra. Additionally, the six helices passageway is also superior to circular passageway in reducing roughness improvement rate (RIR) by roughly 87% compared with RIR 67.7% for the circular passageway.

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5

Kumar, Rahul, Qasim Murtaza und R. S. Walia. „Three Start Helical Abrasive Flow Machining For Ductile Materials“. Procedia Materials Science 6 (2014): 1884–90. http://dx.doi.org/10.1016/j.mspro.2014.07.220.

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6

Brar, B. S., R. S. Walia, V. P. Singh und M. Sharma. „A Robust Helical Abrasive Flow Machining (HLX-AFM) Process“. Journal of The Institution of Engineers (India): Series C 94, Nr. 1 (Januar 2013): 21–29. http://dx.doi.org/10.1007/s40032-012-0054-9.

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7

Li, Junye, Shangfu Zhu, Jinbao Zhu, Chengyu Xu, Hengfu Zhang, Guangfeng Shi, Weihong Zhao und Jianhe Liu. „Quality prediction of polygonal helical curved tube by abrasive flow precision machining“. International Journal of Advanced Manufacturing Technology 119, Nr. 1-2 (09.11.2021): 827–39. http://dx.doi.org/10.1007/s00170-021-07984-6.

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8

Butola, Ravi, Qasim Murtaza, R. S. Walia und Pradeep kumar. „Two start and Three Start Helical Abrasive Flow Machining for Brittle Materials“. Materials Today: Proceedings 4, Nr. 2 (2017): 3685–93. http://dx.doi.org/10.1016/j.matpr.2017.02.263.

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9

Wang, A. Cheng, Ken Chuan Cheng, Kuan Yu Chen und Yan-Cherng Lin. „Enhancing the Surface Precision for the Helical Passageways in Abrasive Flow Machining“. Materials and Manufacturing Processes 29, Nr. 2 (Februar 2014): 153–59. http://dx.doi.org/10.1080/10426914.2013.852204.

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10

Wang, A. Cheng, Ken Chuan Cheng, Kuan Yu Chen und Cheng Chin Chien. „Elucidating the optimal parameters of a helical passageway in abrasive flow machining“. International Journal of Surface Science and Engineering 9, Nr. 2/3 (2015): 145. http://dx.doi.org/10.1504/ijsurfse.2015.068239.

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11

Chen, Kuan-Yu, und Ken-Chuan Cheng. „A study of helical passageways applied to polygon holes in abrasive flow machining“. International Journal of Advanced Manufacturing Technology 74, Nr. 5-8 (11.06.2014): 781–90. http://dx.doi.org/10.1007/s00170-014-5940-2.

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12

Sankar, M. Ravi, V. K. Jain und Janakarajan Ramkumar. „Effect of Abrasive Medium Ingredients on Finishing of Al Alloy and Al Alloy/SiC Metal Matrix Composites Using Rotational Abrasive Flow Finishing“. Applied Mechanics and Materials 110-116 (Oktober 2011): 1328–35. http://dx.doi.org/10.4028/www.scientific.net/amm.110-116.1328.

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Al alloy/SiC composites possess better mechanical and physical properties thus finding applications in automotive, sports, and aerospace. In some cases, these components require nanolevel finished surface. But, traditional abrasive finishing processes are labor intensive, time consuming and confined to only simple geometries. Abrasive flow finishing (AFF) is one of the advanced finishing processes that can be used to finish complex surfaces by flowing polymer based abrasive medium but its finishing rate is low. In the present work, Rotational-AFF (R-AFF) process is developed where in workpiece rotates about its axis. This rotation provides the dynamic motion (additional force and velocity components) to the workpiece. By cumulative effect of workpiece rotation and medium reciprocation, the active abrasive particles try to abrade the workpiece in a helical path. Thus, finishing length and finishing rate both increase. In AFF process, because of more finishing time medium undergoes chemical change or degradation (loses its viscosity) because of continuous shearing and rise in temperature. Therefore the effect of medium shear viscosity variation with the temperature is studied to understand how the viscosity reduces with the temperature. Later complete experiments are conducted on R-AFF process by varying plasticizer to polymer volume ratio and polymer to abrasive ratio. The finishing from micron surface topography to nanosurface topography is studied using atomic force microscopy.

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13

Ansari, Irfan Ahmad, Kamal K. Kar und J. Ramkumar. „Effect of ground tire rubber media's viscoelasticity and flow passage geometry on the abrasive flow finishing of helical gear“. Journal of Manufacturing Processes 101 (September 2023): 219–33. http://dx.doi.org/10.1016/j.jmapro.2023.06.012.

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14

Pischan, Matthias. „Deburring of Cross Holes in Titanium Using Industrial Robots“. Advanced Materials Research 769 (September 2013): 147–54. http://dx.doi.org/10.4028/www.scientific.net/amr.769.147.

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In aircrafts, hydraulic systems control moveable parts. For example parts like the front strut or the landing flaps. These parts are usually made from aluminium or titanium. Due to an increasing number of functions these valves show an increasing number of cross holes. The production process causes burrs at the intersection of the holes. Until now these burrs cant be removed reliably by an automated process. Remaining burrs can influence dimensional tolerances and reduce the efficiency and technical lifetime of the component. In some applications cross holes are used for the lubricant and coolant supply. In this case burrs can lead to blockades of critical passages or cause turbulences in the fluid. This can lead to leakage or bursting of the valve. Hence an uncontrolled removal of the burr during operation must be avoided. The consequence of these basic conditions is a time consuming manual deburring process. An automated deburring process of cross holes with industrial robots is usually performed with flexible abrasive brushes. Alternatively processes like AFM (Abrasive Flow Machining), ECM (Electro Chemical Machining) or TEM (Thermal Energy Machining) are used. Those processes are very efficient but require specialized equipment and cleaning processes for the used chemicals and the remaining abrasive paste. So they are not suitable for the deburring of safety related parts. This paper presents an experimental based approach for the robot based deburring of cross holes using industrial robots. For the deburring of cross holes several special tools are available. This article gives a short overview over the specific advantages and disadvantages of these tools. As the investigations revealed the best results can be achieved using the so called Orbitool developed by JWDone. The Orbitool is a tungsten carbide cutter developed for the deburring of cross holes. A better control of the required dimension at the intersection compared to brushes and other deburring methods is possible. Furthermore the tool can be used on machine tools and industrial robots and is flexible to a huge variety of bore diameters. The tool mainly consists of a ball shaped carbide milling cutter with a protective disk which is made of polished steel and a shaft of tool steel. To remove the burr the tool is moved along the bore axis into the smallest of the intersecting holes until the tip of the tool is close to the intersection. Then the tool is moved in radial direction to the bore surface until the tool axis corresponds to the interpolation diameter. This causes a deflection of the tool. In this situation only the protective disk is in contact with the bore surface. While the tool rotates it is moved towards the intersection in a helical motion. When the tool tip has reached the intersection the cutting edges get in contact with intersection and the deburring process begins. After the tool has passed the whole intersection it stops its rotation and is moved to the bore hole centre and then moved out of the workpiece. This paper deals with the optimization of the deburring process. The result mainly depends on the parameters movement speed of the robot, slope of the helical movement and rotational speed of the tool. The experiments are planned using DOE (Design Of Experiment) methods. Initial values for the optimization of the movement speed were determined by grid encoder measurements. Robotic specific parameters like the number of interpolating points and the influence of the path smoothing caused by the controller were also investigated. For the analysis of the burr and the secondary burr an optical 3-D measurement system is used. The results show that with the presented approach the burrs can be reliably removed. Before the deburring process the average burr height is about 60 μm and can be reduced so that there is no secondary burr visible. The result is a chamfer between 150 μm and 85 μm that depends on the process parameters. It can be demonstrated that a chamfer that is smaller than 100 μm leads to a secondary burr. Anyway the cycle time can be reduced from about 3 minutes for manual deburring to 30 seconds using an industrial robot. Additional wear analysis show that about 200 bore holes can safely be deburred.

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15

Flögel, Karsten, und Fabian Faltin. „Waterjet Turning of Titanium Alloys“. Advanced Materials Research 769 (September 2013): 77–84. http://dx.doi.org/10.4028/www.scientific.net/amr.769.77.

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Titanium alloys offer outstanding properties with regard to its strength to density ratio and a good corrosive resistance in air atmospheres. Substantial advancements could be made by using titanium alloys, in particular for applications in the aerospace industry and medical engineering. However, no product innovation is possible without an appropriate machining technology. For example, low thermal conductivity and hot hardness lead to limitations regarding the applicable machining parameters, particularly for continuous cutting operations. Turning of high performance materials sets high demands on machine tools and especially on the used cutting tools. For conventional continuous cutting of titanium alloys the tool life time and therefore the tool life volume is limited due to the thermal mechanical behaviour. Depending on the chemical and structural composition of the alloy, conventional cutting operations can rarely be regarded as an economic solution. The Abrasive Waterjet Turning process (AWJT) represents a promising alternative manufacturing method to produce rotation-symmetrically or helical parts made of difficult to machine materials. The AWJT process combines the kinematics of conventional turning methods with process-specific advantages of the abrasive waterjet machining. The main advantages are the high variety of machinable materials, the long life time T of the focus nozzles of at least 300 minutes and its independence of the material to be processed. Furthermore, material-inhomogeneity or the initial geometrical contour of the workpiece cannot result in tool failures. An interaction of workpiece and tool known from conventional cutting processes cannot occur. An investigation on hyper eutectic aluminium alloys has shown that AWJT is an economic manufacturing process regarding the resulted material removal rates Qw and tool life volumes. The resulting roughnesses and roundnesses are comparable to a rough turning operation. In addition, AWJT results in a lower hardness penetration depth tw in comparison to conventional turning. Machining of titanium alloys with cylindrical and external turning operations as well as grooving is the next step in the experimental investigation of the machinability of difficult to machine materials with AWJT. Therefore, the objective of the presented work is to provide a model for predicting the material removal rate, the cylindrical roundness and the surface roughness of waterjet turning of the titanium alloy Ti6Al4V. In a screening experiment the significant setting parameters were identified and an adequate range of parameter settings for the response surface study was determined. The tested parameters were the feed rate vf, the abrasive flow rate m and particle size dp, the depth of cut dc and the rotational speed n of the workpiece. It is shown that in relation to the material removal rate Qw linear main effects as well as interaction effects are significant. The developed second-order-regression-model includes these linear main and interaction effects and the quadratic effects of the relevant setting parameters. Furthermore, the achieved material removal rates, tool life volumes, cylindrical roundness and surface quality are used as target values. Additionally the changes like plastic deformations and grain damages in the rim zone were compared to conventional machined parts. Relating to the material removal rate Qw, up to 2.5 cm³/min could be achieved for AWJT at a maximum height of profile Rz below 100 microns. Furthermore, the investigation resulted in a maximum tool life volume of 750 cm³ at a given nozzle life time. The results show that AWJT can be used as an economic alternative manufacturing process for rough turning of titanium alloys.

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16

Ansari, Irfan Ahmad, Dipti Sharma, Kamal K. Kar und Janakarajan Ramkumar. „Investigation on Precision Finishing of Helical Gears Using Newly Developed Silicon Carbide Mixed Styrene Butadiene Media and Abrasive Flow Finishing Process“. Current Nanomaterials 06 (08.02.2021). http://dx.doi.org/10.2174/2405461506666210208124353.

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The good surface finish of gears is one of the critical parameters which leads to its noise-free operation, efficient power transmission, and longer service life. However, most of the gear manufacturing processes do not produce a good surface finish. Therefore, gears need post-processing to finish their surface. Out of several methods of gear finishing like gear grinding, lapping, and honing, the abrasive flow finishing process offers more flexibility due to its self-deformable abrasive medium which can easily flow across complex internal or external geometry. The present study aims to improve the surface finish of helical gear by abrasive flow finishing (AFF) by experimentally identifying the optimum range of the potential input process parameters. An AFF set up was used for gear finishing by using a medium of styrene-butadiene and soft silicone polymer, Silicon carbide abrasive, and silicone oil as a blending agent. A special fixture was developed comprising of five parts namely spider, mandrel, upper, middle, and bottom cylinder with a circumferential hole, which allows the back and forth movement of AFF medium through the annular volume between fixture and gear. Further, an experimental investigation of process parameters like viscosity, effect of percentage of various components in medium, operating pressure, and helix angle of helical gears have been studied on percentage improvement of surface roughness (Ra) value of the gear. It is found that the concentration of abrasives in media and extrusion pressure were the two most significant parameters that have a maximum effect on the percentage reduction in surface roughness and finishing rate. Results show that the optimum combination of the extrusion pressure and abrasive weight percentage is 38 bar and 40 % that produces best results of around 76 and 69 % improvement in Ra for gear of helix angle 30 degree and 45 degree respectively.

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17

Rana, Vivek, Anand Petare, Neelesh Kumar Jain und Anand Parey. „Using abrasive flow finishing process to reduce noise and vibrations of cylindrical and conical gears“. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 28.01.2022, 095440542210758. http://dx.doi.org/10.1177/09544054221075875.

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This paper reports on reduction of noise and vibrations of cylindrical and conical gears through simultaneous reduction in their microgeometry errors, functional parameters, and surface roughness by finishing them with abrasive flow finishing (AFF) process. Previously identified optimum values of AFF medium viscosity and finishing time were used during AFF of the chosen gears. Noise and vibrations characteristics of the unfinished gears and the AFF finished gears were studied by varying motor speed and applied load at four levels each. An indigenously developed test rig was used for spur and straight bevel gears whereas drivetrain diagnostic simulator was used for helical gears. Indigenously developed dual flank roll tester was used to evaluate functional parameters of the unfinished and the best finished gears by AFF process. It was found that AFF process simultaneously reduced microgeometry errors, functional parameters, maximum and average values of surface roughness of spur, helical, and straight bevel gears. It reduced noise and vibration by 5.2 dBA and 5.3 m/s2 for spur gears, by 3.4 dBA and 7.5 m/s2 for helical gears, and by 4.6 dBA and 4 m/s2 for straight bevel gears. This study proves that AFF is an easy-to-operate and effective process for reducing noise and vibrations of cylindrical and conical gears through simultaneous reduction in their microgeometry errors, functional parameters, and surface roughness values. Outcome of this work will be helpful for various manufactures and users of different types of gears.

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