Parametric investigation of thermal additive centrifugal abrasive flow machining process for enhancing productivity

Abstract

Thermal additive centrifugal abrasive flow machining hybrid of abrasive flow machining caters to low material removal issues which enhances the acceptability of the process. The present investigation investigates the different centrifugal force-generating electrode geometry performances in the thermal additive centrifugal abrasive flow machining process. The L27 orthogonal array is used for optimizing the process parameters (electrode type, current supply, and the duty cycle) and their effect on material removal and percentage improvement in surface finish (%Δ Ra) are analyzed. Based on the percentage contribution obtained from Taguchi analysis, electrode type is the prominent parameter for material removal (88.27%) and %Δ Ra (78.54%) followed by current (7.43% for material removal and 13.92% for %Δ Ra) and duty cycle (3.95% for material removal and 6.42% for %Δ Ra). The spline electrode with a curved blade is found optimum with 10 A current and 0.76 duty cycle. The average experimental value based on the design of the experiment and the predicted value for material removal is 10.373 and 10.881 mg, respectively. The average experimental value and the predicted value for percentage improvement in the surface are 42.24% and 43.71%, respectively. The percentage error between the predicted and experimental values for material removal and %Δ Ra is 4.66% and 3.15%, respectively.