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Machine Tool Laboratory

CNC Lathe

CNC Vertical Machining Center

HMT Lathe

NC Lathe

 

 

 

 

 

Micro-ECM

Micro-EDM

 

Ultrasonically Assisted Abrasive Flow Machining (UAAFM)

Facility developed under: DST Project No: SR/S3/MERC-106/2007

Principal Investigator: Dr. Apurbba Kumar Sharma, Associate professor

Graduated students: 02 (Ph. D.) and 05 (M. Tech.)

Patents: 02

Publications: 08 (Journal) and 14 (conference)

Description of facility

Traditionally, AFM needs to be improved with overall performance for effectively finishing high strength advanced materials. Ultrasonic Assisted Abrasive Flow Machining (UAAFM) is a hybrid machining which introduces ultrasonic vibrations to the work piece to enhance interaction of the active abrasive particles with the target surfaces. Consequently, improved machining action can be achieved during the process. Performances of the hybrid AFM processes were evaluated using the laboratory developed multi variant AFM setup (Figure 1). A multifunctional tooling and a new media were developed to finish difficult to machine materials such as Inconel 718 and EN8 steel.

 

 

 

 

 

 

 

 

 

 

 

Figure 2a shows the UAAFM arrangement used for finishing of bevel gears. The two medium cylinders act as the reservoir for the medium that contains SiC abrasive particles. The medium cylinders get driven by the hydraulic cylinders placed next to them (Figure 2a). The medium is made to move from one cylinder to the other through the work piece contact placed inside the work piece fixture (Teflon tooling). The pinion, in relation to the actuator and setup, was made to vibrate in Z-direction perpendicular to the abrasive medium flow direction (X-axis). The magnitude of displacement is controlled in only one direction (Z-axis) using the KC-N15 amplifier and the computer. The actual mounting of the bevel gear inside the Teflon tooling is shown in Figure 2b.

 

 

 

 

 

 

 

Process performance

Figs. 3 a-b clearly show that rate of improvement in surface finish (SF) and material removal (MR) in UAAFM pertaining to 5 min of machining is even higher than the values after 15 min of machining through conventional AFM although the initial surface finish in both the cases were similar (Ra=1.8 mm). This further clarifies that the rate of removal and surface finish improvement during the initial cycles in UAAFM are significantly higher than that of AFM. After 5 and 15 min of UAAFM, the improvements in SF and MR are 73.12% and 24 mg, respectively.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 4a–c illustrate the surface topographies of the work piece surface before finishing, after finishing through conventional AFM and UAAFM processed surfaces. It was observed that there was a 55% rate of improvement in the surface of the gears finished through classical AFM, while an improvement rate of 73.12% was recorded after finishing the part through UAAFM for similar machining interval. The typical profiles presented show significantly reduced peaks in case the UAAFMed surface.

 

 

 

 

 

 

 

 

 

 

 

Figure 5a–b clearly show that before UAAFM process, the work surface of the as received gear tooth contains scratches, micro-cracks, pits etc. Micro-graphs of UAAFMed surface morphology are shown in Figure 5c–d. The UAAFM finished surface presents a glazed appearance, while very light feed marks (due to gear hobbing) and scratches by the medium abrasives can be identified. Thus, the effectiveness of the application of the additional effect in terms of the external ultrasonic vibration could be realised.

Details of research outputs

(1) Ph. D. Completed

  • Dr. Rajesha S. (July, 2009 – Feb, 2011) on “Some Studies to Enhance the Capabilities of Abrasive Flow Machining Process” (Co-supervisor: Prof. P. Kumar).

 

  • Dr. Gudipadu Venkatesh (Jan, 2012 – May, 2015) on “Performance Analysis of Ultrasonic Assisted Abrasive Flow Machining Process” (Co-supervisor: Prof. P. Kumar).

(2) Patents

  1. Rajesha S., G. Venkatesh, A. K. Sharma, Pradeep Kumar. “A Natural Polymer Abrasive Media for the Abrasive Flow Machining and A Process for Preparation Thereof” (Application no.1349/Del/2011 on date 09.05.2011).       

                                   

  1. A.K. Sharma, Pradeep Kumar, Rajesha S. “An Improved Ultrasonic Abrasive Flow Machining and A Device Therefor”  (Application no. 3578/Del/2011 on date 09.12.2011)          

(3) Journal publications

  1. Venkatesh, G., Sharma, A. K., & Kumar, P. (2015). On ultrasonic assisted abrasive flow finishing of bevel gears. International Journal of Machine Tools and Manufacture, 89, 29-38.

 

  1. Gudipadu, V., Sharma, A. K., & Singh, N. (2015). Simulation of media behaviour in vibration assisted abrasive flow machining. Simulation Modelling Practice and Theory, 51, 1-13.

 

  1. Sharma, A. K., Venkatesh, G., Rajesha, S., & Kumar, P. (2015). Experimental investigations into ultrasonic-assisted abrasive flow machining (UAAFM) process. The International Journal of Advanced Manufacturing Technology, 80(1-4), 477-493.

 

  1. Cheema, M. S., Venkatesh, G., Dvivedi, A., & Sharma, A. K. (2012). Developments in abrasive flow machining: a review on experimental investigations using abrasive flow machining variants and media. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 226(12), 1951-1962.

 

  1. Venkatesh, G., Singh, T., Sharma, A. K., & Dvivedi, A. (2014). Finishing of Micro-channels Using Abrasive Flow Machining. In Proceedings of the International Conference on Research and Innovations in Mechanical Engineering (pp. 243-252). Springer, New Delhi.

 

  1. Venkatesh, G., Sharma, A. K., & Kumar, P. (2015). Fine finishing of SiC microchannels using abrasive flow machining. International Journal of Engineering & Material Sciences, 22, 297-306.

 

  1. Arora, G., Sharma, A. K., Bhowmik, P., & Priyadarshini, S. An FEM Approach to Analysis of Media used in the Spiral Flow Assisted Abrasive Flow Machining. International Journal of Mechanical Engineering Research, 635.

 

  1. Rajesha, S., Sharma, A. K., & Kumar, P. (2011). Some Studies on Performance of a Natural Polymer Media for Abrasive Flow Machining. Supplemental Proceedings: General Paper Selections, Volume 3, 333-340.

 

(4) Conference publications

1.

Rajesha S., Sharma A. K., Kumar Pradeep, (2009), “Hybrid Abrasive Flow Machining Process: A Brief Review”, Proc. National Conference on Recent Advances in Mechanical and Production Engineering RAMP 2009, College of Technology, Pantnagar, February 12-14, 2009, pp 366-374.

2.

Rajesha S., Sharma A. K, Kumar Pradeep, (2010), “Influence of Parameters on Process Performance During Electro Discharge Machining of Inconel-718”, Proceedings: TMS (The Minerals, Metals & Materials Society) -2010 , 139th Annual Meeting & Exhibition, Seattle, Washington USA,  February 14-18, 2010, Volume 3, pp. 841-848.

3.

G. Venkatesh, S. Rajesha, A. K. Sharma, Kumar Pradeep (2010), “Performance Evaluation of a New Abrasive Carrier for Abrasive Flow Machining”, National Conference on Recent Innovations in Production Engineering, RIPE - 2010, MIT Campus - Anna University Chennai, April 16-17, 2010, pp. B 97-100. 

4.

Rajesha S., Sharma A. K, Kumar Pradeep, (2010), “Effect of Process Parameters on Performance of WEDM while Machining Inconel 718”, Proceeding: International Conference on Frontiers in Mechanical Engineering, FIME-2010, NITK, Surathkal, May 20-22, 2010, pp. 162-167.

5.

Rajesha S., Sharma A.K, Kumar Pradeep, (2010), “Development and Performance Evaluation of Alternative Media for Abrasive Flow Machining”, Proceeding: International Conference on Frontiers in Mechanical Engineering, FIME-2010, NITK, Surathkal, May 20-22, 2010, pp. 168-173.

6.

Rajesha S., A. K. Sharma, Kumar Pradeep, (2010), “Some Aspects of Surface Integrity Study of Electro Discharge Machined Inconel 718”, Proceedings of the 36th International MATADOR Conference,  The University of Manchester, United Kingdom, July 14-16, pp. 439-444.

7.

Rajesha S., Pramod Kumar Patnaik, Apurbba Kumar Sharma, Kumar Pradeep (2010), “Surface Integrity Evaluation of Electro Discharge Machined Inconel 718” 3rd International and 24th AIMTDER-2010, Andhra University, Visakhapatnam December 13-15, 2010, pp. 259-264. 

8.

Rajesha S., G. Venkatesh, Apurbba Kumar Sharma, Kumar Pradeep (2010), “Performance Evaluation of a Newly Developed Media for AFM Using Taguchi’s Orthogonal Arrays”, 3rd International and 24th AIMTDER-2010, Andhra University, Visakhapatnam, December 13-15, 2010, pp. 1187-1192.

9.

Rajesha S., A. K. Sharma, Kumar Pradeep, (2010), “Influence of Process Parameters on Material Removal Rate While EDMing Inconel 718”, Second International Conference CPIE 2010, NIT Jalandhar, 3-5 December, 2010, pp. 733-737.

10.

Rajesha S., A.K. Sharma, Kumar Pradeep (2011) “Some Studies on Performance of A Natural Polymer Media for Abrasive Flow Machining”, Proceedings: TMS -2011, 140th Annual Meeting and Exhibition, February 27 - March 3, 2011 San Diego, California, Volume 3[DOI: 10.1002/9781118062173.ch41] pp. 333–340

12.

Rajesha S., A.K. Sharma, Kumar Pradeep (2012),” Tool Wear Analysis While Electro Discharge Machining of Inconel 718” WASET 2012 Zurich, Switzerland, January 15-17, 2012, pp. 186-191.

13

Gudipadu Venkatesh, A. K. Sharma, Pradeep Kumar, “Influence of Process Parameters on Performance of Natural Polymer Media for Abrasive Flow Machining of Brass alloy All India Machine Tool Design and Research (AIMTDR-2012), Dec 14-16, 2012, Kolkata, Vol. 1, pp.577-582.

14

Gudipadu Venkatesh, A. K. Sharma, Pradeep Kumar, (2012), “A Taguchi’s Approach to Characterization and Performance evaluation of a Natural Polymer Media for Abrasive Flow Machining”, Advances In Materials And Processing: Challenges and Opportunities’ (AMPCO),  (Poster Presented in AMPCO-2012).