Finite element analysis of media used in the centrifugal force assisted abrasive flow machining process

Abstract

Abrasive flow machining (AFM) is a non-conventional finishing process that provides a high level of surface finish and close tolerances with an economically acceptable rate of surface generation for a wide range of industrial components. AFM deburrs and polishes by forcing an abrasive laden media (elastic/viscoelastic polymer) across the workpiece surface. Abrasion occurs only where the media flow is restricted; other areas remain unaffected. One serious limitation of AFM processes is a low material removal rate. An effort has been made towards the performance improvement of this process by applying centrifugal force on the abrasive media using a rotating rod introduced in the workpiece passage. This variant of AFM, called centrifugal force assisted abrasive flow machining (CFAAFM), has been developed. This paper presents finite element modelling (FEM) of a polymer-based non-Newtonian viscoelastic fluid used in the CFAAFM process and the same is used to evaluate the resultant pressure, velocity, and radial stresses during a working cycle. All FEM analyses were performed using a commercial finite element package ANSYS. The results are compared with the data available in the literature, and close agreement has been found between the two.