Cutting factors and testing of highly viscoelastic fluid abrasive flow machining

Dong, Zhiguo; Zhang, Yuchao; Lei, Hongbo

doi:10.1007/s00170-021-06619-0

Cited by 9 publications

(3 citation statements)

References 20 publications

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“…The main reason is that the mold is repeatedly heated [28] and cooled during the wax injection process. Ongoing research is focused on improving the surface roughness of the CCC by abrasive blasting, abrasive flow machining [29], electrochemical polishing, chemical polishing, laser polishing, or ultrasonic cavitation abrasive finishing. In various industries, hydrogen [30,31] is widely applied as a high-performance gaseous cooling medium since its thermal conductivity is higher than all other gases.…”

Section: Resultsmentioning

confidence: 99%

Effects of Different Mold Materials and Coolant Media on the Cooling Performance of Epoxy-Based Injection Molds

Kuo

Zhu

et al. 2022

Polymers

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Metal additive manufacturing techniques are frequently applied to the manufacturing of injection molds with a conformal cooling channel (CCC) in order to shorten the cooling time in the injection molding process. Reducing the cooling time in the cooling stage is essential to reducing the energy consumption in mass production. However, the distinct disadvantages include higher manufacturing costs and longer processing time in the fabrication of injection mold with CCC. Rapid tooling technology (RTT) is a widely utilized technology to shorten mold development time in the mold industry. In principle, the cooling time of injection molded products is affected by both injection mold material and coolant medium. However, little work has been carried out to investigate the effects of different mold materials and coolant media on the cooling performance of epoxy-based injection molds quantitatively. In this study, the effects of four different coolant media on the cooling performance of ten sets of injection molds fabricated with different mixtures were investigated experimentally. It was found that cooling water with ultrafine bubble is the best cooling medium based on the cooling efficiency of the injection molded parts (since the cooling efficiency is increased further by about 12.4% compared to the conventional cooling water). Mold material has a greater influence on the cooling efficiency than the cooling medium, since cooling time range of different mold materials is 99 s while the cooling time range for different cooling media is 92 s. Based on the total production cost of injection mold and cooling efficiency, the epoxy resin filled with 41 vol.% aluminum powder is the optimal formula for making an injection mold since saving in the total production cost about 24% is obtained compared to injection mold made with commercially available materials.

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Section: Resultsmentioning

confidence: 99%

Effects of Different Mold Materials and Coolant Media on the Cooling Performance of Epoxy-Based Injection Molds

Kuo

Zhu

et al. 2022

Polymers

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“…12,13 Furthermore, the medium pressure acts on the hemispherical surface of active abrasive particle in the normal direction of workpiece surface, providing normal force for the particles to penetrate into surface material. [14][15][16] It is obvious that tangential force on the active abrasive particle is absent in this model, and scratch depth is dependent on the medium pressure and particle size.…”

Section: Introductionmentioning

confidence: 99%

Modeling and quantitative study of soft contact between abrasive medium and active abrasive particles in abrasive flow machining

Fan

Sun

Liu

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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In abrasive flow machining (AFM), material is abraded by active abrasive particles powered by solid-liquid contact between them and the abrasive medium. This contact characteristic is a key and unfortunately it is investigated scarcely.In this work, a soft-contact model was firstly proposed. Soft-contact parameters including protrusion ratio and covering inclination angle were then defined to characterize soft-contact characteristics. Finally, the effect of medium pressure and particle diameter on soft-contact parameters was studied by full factorial design. Results showed that average scratch depth of single active abrasive particle increases with increasing particle diameter and medium pressure. In addition, active abrasive particles are actually deeply wrapped to a large proportion by abrasive medium, and the descriptive protrusion ratio decreases with increasing medium pressure and particle diameter. Moreover, medium pressure offers tangential and normal force for active abrasive particle through a covering inclination angle, and the angle increases with increasing medium pressure and particle diameter. It provides guidance for further improvement of prediction accuracy of material removal in AFM process.

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“…A typical abrasive particle size lies in the range of 32-1035 µm, as mentioned by Trengove [14], while concentration of the abrasive may approach 80%, after which the medium begins to act inefficiently, as demonstrated by Kar et al [15]. An interesting method to assess the cutting forces of abrasive flow machining using a two-phase viscoelastic flow approach was proposed by Dong et al [16] This method combines an analytical model for calculating the cutting factors and an experimental technique to calibrate this model. While this approach provides an interesting insight into the abrading behavior of AFM media and offers a new perspective for the optimization of the media composition, it cannot directly be applied to predict the material removal (MR) during the AFM process and, therefore, to determine the machining allowances of the parts to be polished.…”

Section: Introductionmentioning

confidence: 99%

Towards the Determination of Machining Allowances and Surface Roughness of 3D-Printed Parts Subjected to Abrasive Flow Machining

Samoilenko

Lanik²,

Braïlovski

2021

JMMP

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Abrasive flow machining (AFM) is considered as one of the best-suited techniques for surface finishing of laser powder bed fused (LPBF) parts. In order to determine the AFM-related allowances to be applied during the design of LPBF parts, a numerical tool allowing to predict the material removal and the surface roughness of these parts as a function of the AFM conditions is developed. This numerical tool is based on the use of a simplified viscoelastic non-Newtonian medium flow model and calibrated using specially designed artifacts containing four planar surfaces with different surface roughnesses to account for the build orientation dependence of the surface finish of LPBF parts. The model calibration allows the determination of the abrasive medium-polished part slip coefficient, the fluid relaxation time and the abrading (Preston) coefficient, as well as of the surface roughness evolution as a function of the material removal. For model validation, LPBF parts printed from the same material as the calibration artifacts, but having a relatively complex tubular geometry, were polished using the same abrasive medium. The average discrepancy between the calculated and experimental material removal and surface roughness values did not exceed 25%, which is deemed acceptable for real-case applications. A practical application of the numerical tool developed was demonstrated using the predicted AFM allowances for the generation of a compensated computer-aided design (CAD) model of the part to be printed.

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Cutting factors and testing of highly viscoelastic fluid abrasive flow machining

Cited by 9 publications

References 20 publications

Effects of Different Mold Materials and Coolant Media on the Cooling Performance of Epoxy-Based Injection Molds

Effects of Different Mold Materials and Coolant Media on the Cooling Performance of Epoxy-Based Injection Molds

Modeling and quantitative study of soft contact between abrasive medium and active abrasive particles in abrasive flow machining

Towards the Determination of Machining Allowances and Surface Roughness of 3D-Printed Parts Subjected to Abrasive Flow Machining

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