Investigation of Material Removal and Surface Topography Formation in Vibratory Finishing

Uhlmann, Eckart; Dethlefs, Arne; Eulitz, Alexander

doi:10.1016/j.procir.2014.03.048

Cited by 48 publications

(19 citation statements)

References 6 publications

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“…Domblesky et al also outlined that the material removal rate which is required in a surface finishing operation is independent of the processing time as the surface roughness saturates over time [118]. Uhlmann et al outline that the material removal rate is dependent on the initial level of surface roughness as well as on the abrasivity of the media [119].…”

Section: Vibratory Polishing Of Hard Coatingsmentioning

confidence: 99%

Recent Progress in Precision Machining and Surface Finishing of Tungsten Carbide Hard Composite Coatings

Micallef

Zhuk²,

Aria

2020

Coatings

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Owing to their high hardness, fracture toughness and oxidation resistance, tungsten carbide (WC) coatings are extensively deposited on parts that operate in demanding applications, necessitating wear, erosion, and corrosion resistance. The application of thick and hard WC coatings has an inevitable effect on the original dimensions of the parts, affecting the geometrical tolerances and surface roughness. The capability of achieving a sub-micron surface finish and adhere to tight geometrical tolerances accurately and repeatably is an important requirement, particularly with components that operate in high-precision sliding motion. Meeting such requirements through conventional surface finishing methods, however, can be challenging due to the superior mechanical and tribological properties of WC coatings. A brief review into the synthesis techniques of cemented and binderless WC coatings is presented together with a comprehensive review into the available techniques which are used to surface finish WC-based coatings with reference to their fundamental mechanisms and capabilities to process parts with intricate and internal features. The binderless WC/W coating considered in this work is deposited through chemical vapour deposition (CVD) and unlike traditional cemented carbide coatings, it has a homogenous coating structure. This distinctive characteristic has the potential of eliminating key issues commonly encountered with machining and finishing of WC-based coatings. Here, six contact and non-contact surface finishing techniques, include diamond turning, precision grinding, superfinishing, vibratory polishing, electrical discharge machining, and electropolishing are discussed along with their current use in industry and limitations. Key challenges in the field are highlighted and potential directions for future investigation, particularly on binderless WC coatings, are proposed herein.

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Section: Vibratory Polishing Of Hard Coatingsmentioning

confidence: 99%

Recent Progress in Precision Machining and Surface Finishing of Tungsten Carbide Hard Composite Coatings

Micallef

Zhuk²,

Aria

2020

Coatings

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“…Workpieces in this set-up are stainless steel rods (1.4301) with a diameter of 39.5 millimetres and a set surface topography, resulting from turning with constant feed rate (Rz & 26 lm). Based on the change in roughness at the rods, a material removal rate and hence the cutting performance of media can be determined, as described by Uhlmann et al [7]. After 300 h of use, the particle tracking experiment is conducted.…”

Section: Experimental Setting and Measuring Devicesmentioning

confidence: 99%

Wear Mechanisms of Ceramic Vibratory Finishing Media

Uhlmann

Eulitz

2018

Nanomanuf Metrol

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Vibratory finishing is a common manufacturing process that can be used for many applications such as deburring, edge rounding and polishing of surfaces. In this process, material removal is caused by an irregular relative motion between workpieces and a bulk of loose abrasive media. A wide variety of media is used, i.e. different shapes, sizes and compositions. The composition of media differs in terms of the binder which can either be resin or ceramic, and the abrasive grains typically being aluminium oxide or silica. Ceramic media, which is the focus of this publication, is the most common media because of its low cost and high material removal rates. At present, there is no sound understanding of the wear of ceramic media. During a vibratory finishing process, each particle of media is in contact more frequently with other particles than with the workpieces. This induces media wear resulting in decreasing media size and under certain conditions, lowering cutting rates. Up to now, wear mechanisms of vibratory finishing media are scarcely understood. In this publication, it is shown that wear mechanisms of conventional grinding tools can be observed on vibratory finishing media too. Media condition is observed at several different times-of-use starting from zero (fresh media) up to 300 h. For the first time, single media particles are tracked over a long time-of-use. This allows for observing certain abrasive grains. Based on microscopy and topographic analyses, wear can be identified on grain level. This reveals the prevailing wear mechanisms of the ceramic media.

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“…A continuum finite element model was successfully used to simulate the flow behavior in a tub vibratory finisher [38]. Extensive experimental investigations indicated that the relative velocity between the workpiece and abrasives is the main factor governing the material removal [39]. Some attempts were conducted to finish blades by using vibratory finishing owing to its considerably lower manufacturing cost and better surface consistency.…”

Section: Vibratory Finishing and Drag Finishingmentioning

confidence: 99%

“…Robot-guided drag finishing using an industrial six-axis robot was developed, in which the workpieces are guided through the resting or vibrating abrasive. This method may improve the reachability of the abrasives [43,44].…”

Section: Vibratory Finishing and Drag Finishingmentioning

confidence: 99%

Machining the Integral Impeller and Blisk of Aero-Engines: A Review of Surface Finishing and Strengthening Technologies

Gao

Wang

et al. 2017

Chin. J. Mech. Eng.

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The integral impeller and blisk of an aero-engine are high performance parts with complex structure and made of difficult-to-cut materials. The blade surfaces of the integral impeller and blisk are functional surfaces for power transmission, and their surface integrity has significant effects on the aerodynamic efficiency and service life of an aero-engine. Thus, it is indispensable to finish and strengthen the blades before use. This paper presents a comprehensive literature review of studies on finishing and strengthening technologies for the impeller and blisk of aero-engines. The review includes independent and integrated finishing and strengthening technologies and discusses advanced rotational abrasive flow machining with back-pressure used for finishing the integral impeller and blisk. A brief assessment of future research problems and directions is also presented.

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Investigation of Material Removal and Surface Topography Formation in Vibratory Finishing

Cited by 48 publications

References 6 publications

Recent Progress in Precision Machining and Surface Finishing of Tungsten Carbide Hard Composite Coatings

Recent Progress in Precision Machining and Surface Finishing of Tungsten Carbide Hard Composite Coatings

Wear Mechanisms of Ceramic Vibratory Finishing Media

Machining the Integral Impeller and Blisk of Aero-Engines: A Review of Surface Finishing and Strengthening Technologies

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