Simulation of abrasive flow machining process for 2D and 3D mixture models

doi:10.1007/s11465-015-0366-6

Front. Mech. Eng.

2015, Vol. 10

Issue (4) : 424-432 https://doi.org/10.1007/s11465-015-0366-6

RESEARCH ARTICLE

Simulation of abrasive flow machining process for 2D and 3D mixture models

Rupalika DASH,Kalipada MAITY(

)

Mechanical Engineering Department, National Institute of Technology, Rourkela 769008, India

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Abstract

Improvement of surface finish and material removal has been quite a challenge in a finishing operation such as abrasive flow machining (AFM). Factors that affect the surface finish and material removal are media viscosity, extrusion pressure, piston velocity, and particle size in abrasive flow machining process. Performing experiments for all the parameters and accurately obtaining an optimized parameter in a short time are difficult to accomplish because the operation requires a precise finish. Computational fluid dynamics (CFD) simulation was employed to accurately determine optimum parameters. In the current work, a 2D model was designed, and the flow analysis, force calculation, and material removal prediction were performed and compared with the available experimental data. Another 3D model for a swaging die finishing using AFM was simulated at different viscosities of the media to study the effects on the controlling parameters. A CFD simulation was performed by using commercially available ANSYS FLUENT. Two phases were considered for the flow analysis, and multiphase mixture model was taken into account. The fluid was considered to be a Newtonian fluid and the flow laminar with no wall slip.

Keywords abrasive flow machining (AFM) computational fluid dynamics (CFD) modeling mixture model

Corresponding Author(s): Kalipada MAITY

Online First Date: 26 November 2015 Issue Date: 03 December 2015

Cite this article:

Rupalika DASH,Kalipada MAITY. Simulation of abrasive flow machining process for 2D and 3D mixture models[J]. Front. Mech. Eng., 2015, 10(4): 424-432.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-015-0366-6
https://academic.hep.com.cn/fme/EN/Y2015/V10/I4/424

Fig.1 Workpiece and fixture

Fig.2 Finite elements domain for the CFD analysis

Fig.3 (a) Arrangement of workpieces with fixtures [10]; (b) 3D meshed model for FLUENT analysis of the passage

Fig.4 Symmetry considered for FLUENT analysis

Tab.1 Simulation parameters for the 2D and 3D model

Fig.5 Finite elements domain for the CFD analysis [8]

Tab.2 Variation of velocity, static pressure, strain rate and shear stress at two different extrusion pressures (data from FLUENT analysis)

Fig.6 Velocity contour from the simulated result

Fig.7 Dynamic pressure contour from the simulated result

Tab.3 Strain rates at different volume fractions

Fig.8 Variation of strain rate at different volume fractions

Tab.4 Depth of indentation at different viscosities

Tab.5 Depth of indentation at different extrusion pressures

Fig.9 MRR for experimental and simulated results

Fig.10 Dynamic pressure contours at different viscosities. (a) 510 Pa·s; (b) 640 Pa·s; (c) 760 Pa·s

Fig.11 Strain rate contours at different viscosities. (a) 510 Pa·s; (b) 640 Pa·s; (c) 760 Pa·s

Fig.12 Velocity contours at different viscosities. (a) 510 Pa·s; (b) 640 Pa·s; (c) 760 Pa·s

Tab.1

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