EVALUATION OF INDUCED SURFACE INTEGRITY IN EXTRUSION HONING PROCESS

Authors

  • Jayasimha SLN Department of Mechanical Engineering, P.E.S College of Engineering, Mandya, Karnataka-571401, India
  • Murali Krishna N L Department of Industrial and Production Engineering, P.E.S College of Engineering, Mandya, Karnataka-571401, India
  • Raju H P Department of Mechanical Engineering, P.E.S College of Engineering, Mandya, Karnataka-571401, India

DOI:

https://doi.org/10.37255/jme.v18i4pp118-129

Keywords:

Extrusion Honing (EH), Surface finish (SF), Material removal (MR), Carrier media, Abrasives.

Abstract

It is vital to achieve desired level of surface texture on exterior surfaces of pre-machined component. The required quality of surface can be obtained on outer surface by conventional deburring process like grinding, honing and so on. But difficulty arises while processing interior surface of components such as micro bores, inlet/outlet valves and so on. It’s a revolutionary micro finishing method that eludes the pressurised flow of media mixed with SiC into restricted passage to achieve the appropriate range of surface texture. Micro machining in this novel technique is a result of abrasion process by removing a minuscule quantity of stock material. The current investigation attempt in knowing the effect of number of passes at specimen entry and exit side of media, and developing a semi-empirical model for evaluating Ra by applying Buckingham’s π theorem. The generated surface produced by process factors such as number of passes, volume fraction, and grit size of abrasives is studied by SEM analysis.

Downloads

Download data is not yet available.

Metrics

Metrics Loading ...

References

Ajiboye, J.S., Jung, KH. and Im, YT., 2010. “Sensitivity study of frictional behavior by dimensional analysis in cold forging.” Journal of Mechanical Science and Technology 24, 115–118.

Ali Abdolahi, Matthias Risto, Rüdiger Haas., 2018. “Non-Dimensional analysis and optimization of EDM drilling process using an innovative function.” Procedia CIRP 68, 248-253.

Bhaumik, Munmun, Kalipada Maity and Kasinath Das Mohapatra., 2016. “Determination of material removal rate and radial overcut in electro discharge machining of AISI 304 using dimensional analysis.” Applied Mechanics and Materials 852, 160-165.

Chen, Tian Xiang, and Cheng Yong Wang., 2012. “Investigation into roughness of surface polished by abrasive water jet with Taguchi method and dimensional analysis.” Materials Science Forum 723, 188-195.

Dariusz Poroś and Stanisław Zaborski., 2009. “Semi-empirical model of efficiency of wire electrical discharge machining of hard-to-machine materials.” Journal of Materials Processing Technology 209, no. 3, 1247-1253.

Hajiahmadi, S., Elyasi, M. and Shakeri, M., 2019. “Investigation of a new methodology for the prediction of drawing force in deep drawing process with respect to dimensionless analysis.” International Journal of Mechanical and Materials Engineering 14, no.14, 1-13.

Ibrahim., A.F., 2014. "Studying material removal in abrasive flow machining by using SiC."International Journal of Current Engineering and Technology 4, no. 5, 3420–3423.

Jain, V.K., and S.G.Adsul., 2000. "Experimental investigations into abrasive flow machining (AFM)." International Journal of Machine Tools and Manufacture 40, no.7, 1003-1021.

Jain, R.K., and V.K.Jain., 2003. "Finite element simulation of abrasive flow machining." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 217, no. 12, 1723-1736.

Jain, Rajendra K., and V.K.Jain., 1999. "Stochastic simulation of active grain density in abrasive flow machining." Journal of Materials Processing Technology 152, no. 1, 17-22.

Jain, R.K., V.K. Jain, and P.K. Kalra., 1999. "Modelling of abrasive flow machining process: a neural network approach." Wear 231, no. 2, 242-248.

Jain, Rajendra Kumar, and Vijay Kumar Jain., 2000. "Optimum selection of machining conditions in abrasive flow machining using neural network." Journal of Materials Processing Technology 108, no. 1, 62-67.

Kumar, A., Kumar, V. and Kumar, J., 2015. “Semi-empirical model on MRR and overcut in WEDM process of pure titanium using multi-objective desirability approach.” Journal of the Brazilian Society of Mechanical Sciences and Engineering 37, 689–721.

Kadu, G.K. Awari, C.N. Sakhale, and J.P.Modak., 2014. “Formulation of mathematical model for the investigation of tool wears in boring machining operation on cast iron using carbide and CBN tools.” Procedia Materials Science 6, 1710-1724.

Kumar, J., Khamba, J.S., 2010. “Modeling the material removal rate in ultrasonic machining of titanium using dimensional analysis.” The International Journal of Advanced Manufacturing Technology 48, 103–119.

Kumar S, Singh R, Batish A, and Singh T., 2017. “Modeling the tool wear rate in powder mixed electro-discharge machining of titanium alloys using dimensional analysis of cryogenically treated electrodes and work piece.” Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering 231, no.2, 271-282.

Kuo-Ming., Tsai, Pei-Jen.,Wang.,2001. “Semi-empirical model of surface finish on electrical discharge machining.”International Journal of Machine Tools and Manufacture 41, no.10, 1455-1477.

Kushwah, S.S., Kasdekar, D.K., and Agrawal, S., 2018. “Mathematical and prediction modeling of material removal rate for evaluating the effects of process parameters.” Ambient Communications and Computer Systems 696, 509-523.

Larry Rhoades., 1991. “Abrasive flow machining: a case study.” Journal of Materials Processing Technology 28, no. 1–2, 107-116.

Mahendra Uttam Gaikwad, Krishnamoorthy A, Vijaykumar S Jatti., 2020. “Predictive analysis of Surface Roughness during EDM machining of NiTi60 alloy using Taguchi technique and Empirical Modeling: A Comparative Investigation.” International Journal of Advanced Science and Technology 29, no. 8, 1745-1753.

Mangesh R. Phate, Shraddha B. Toney., 2019. “Modeling and prediction of WEDM performance parameters for Al/SiCp MMC using dimensional analysis and artificial neural network.” Engineering Science and Technology, an International Journal 22, no.2, 468-476.

Mangesh Phate and Tatwawadi, V.H., 2015. “Mathematical models of material removal rate and power consumption for dry turning of ferrous material using dimensional analysis in Indian prospective.” Jordan Journal of Mechanical and Industrial Engineering 9, no.1, 27-38.

Mohankumar, V., Kanthababu, M., 2020. “Semi-empirical model for depth of cut in abrasive water jet machining of metal matrix composites.” Journal of the Brazilian Society of Mechanical Sciences and Engineering 42, 507.

Murali Krishna., N.L and H. P. Raju., 2014. "Extrusion honed surface characteristics of Inconel 625 fabricated by EDM for square shape." International Journal of Engineering Research and Application 4, no.6 (2014):68-72.

Murali Krishna, N.L., and H.P.Raju., 2014. "Acoustic emission characteristics of Inconel 718 and Inconel 625 micro finished by extrusion honing process." International Journal of research in advent Technology 2 (2014):81-86.

Nishant Kumar Singh, Yashvir Singh and Abhishek Sharma., 2020. “A mathematical model to assess the material removal rate during gas-assisted electrical discharge drilling process.” International Journal of Mathematical, Engineering and Management Sciences 5, no. 6, 1333-1344.

Nishant K. Singh, Sanjeev Kumar, Yashvir Singh, and Varun Sharma., 2020. “Predictive analysis of surface finish in gas-assisted electrical discharge machining using statistical and soft computing techniques” Surface Review and Letters 27, no. 04, 1950126-11.

Patil, N.G., Brahmankar, P.K., 2010. “Determination of material removal rate in wire electro-discharge machining of metal matrix composites using dimensional analysis.” The International Journal of Advanced Manufacturing Technology 51, 599–610.

Patel, J.D. and Maniya, K.D., 2019. “Development of semi empirical model on material removal rate in WEDM process for aluminium metal matrix material using dimensional analysis.” International Journal Manufacturing Research 14, no. 3, 217–230.

Pei-Jen., Wang and Kuo-Ming., Tsai., 2001. “Semi-empirical model on work removal and tool wear in electrical discharge machining.” Journal of Materials Processing Technology 114, no. 1, 1-17.

Raju, H.P., K.Narayanasamy, Y.G.Srinivasa, and R.Krishnamurthy., 2005. "Characteristics of extrude honed SG iron internal primitives." Journal of Materials Processing Technology 166, no. 3, 455-464.

Raju, H.P., K. Narayanasamy, Y.G. Srinivasa, and R.Krishnamurthy., 2003. "Material response in extrusion honing." Journal of materials science letters 22, no. 5,367-370.

Ravindranadh Bobbili, V. Madhu, A.K. Gogia, 2015. “Modelling and analysis of material removal rate and surface roughness in wire-cut EDM of armour materials.” Engineering Science and Technology, an International Journal 18, no.4, 664-668.

Roy G.G, R.Nandan and T.DebRoy., 2006. “Dimensionless correlation to estimate peak temperature during friction stirs welding.” Science and Technology of Welding and Joining 11, no.5, 606-608.

Rupesh Chalisgaonkar and Jatinder Kumar., 2014. “Parametric optimization and modelling of rough cut WEDM operation of pure titanium using grey-fuzzy logic and dimensional analysis.” Cogent Engineering 1, no.1, 1-28.

Sachin Singh, M. Ravi Sankar., 2015 “Design and performance evaluation of abrasive flow finishing process during finishing of stainless-steel tubes.” Materials Today Proceedings 2, no.5,(2015):3161-3169.

Sankar, V.K. Jain, J. Ramkumar., 2010 "Rotational abrasive flow finishing (R-AFF) process and its effects on finished surface topography." International Journal of Machine Tools and Manufacture 50, no.07, 637-650.

Singh, D., and Shukla, R.S., 2020. “Integration of quality characteristics models as a software-based graphical interface for machining of AA6351 aluminum alloy using abrasive water jet process.” Journal of Brazilian. Society of Mechanical Sciences and Engineering 42, no.6.

Singh, N.K., Singh, Y., 2019. “Experimental investigation and modeling of surface finish in argon-assisted electrical discharge machining using dimensional analysis”. Arabian Journal for Science and Engineering 44, 5839–5850.

Singh., and S.Mittal., 2015 "Effect of process variables on material removal rate during finishing of Al-6061 alloy using abrasive flow machining." International Journal of Current Engineering and Technology 5, no. 4, 2449-2453.

Singh, S. Prakash, C. Antil, P. Singh, R. Królczyk, G. and Pruncu, C.I. 2019. “Dimensionless analysis for investigating the quality characteristics of aluminium matrix composites prepared through fused deposition modelling assisted investment casting.” Materials 12, no.12, 1907.

Sudhakara, D., Suresh, S. and Vinod, B., 2020 "Experimental study on abrasive flow machining (AFM): new approach for investigation on nano-SiC in the improvement of material removal and surface finishing.” Journal of Bio- and Tribo- Corrosion 6, no.01 ,1-12.

Wang., J., 2007. “Predictive depth of jet penetration models for abrasive water jet cutting of alumina ceramics.”International Journal of Mechanical Sciences 49, no.3, 306-316.

Yahya and C D Manning., 2004. “Determination of material removal rate of an electro-discharge machine using dimensional analysis.” Journal of Physics D: Applied Physics 37, no.10, 37 1467.

Yunus Mohammed, and Mohammad S. Alsoufi. 2020 "Application of response surface methodology for the optimization of the control factors of abrasive flow machining of multiple holes in zinc and Al/SiCp MMC wires." Journal of Engineering Science and Technology 15, no. 1, 655-674.

Zhang, G., Sun, Y., Liu, X, Liaoyuan Wang and Dunwen Zuo. 2021. “Prediction of erosion volume of PDMS by cryogenic micro-abrasive jet machining based on dimensional analysis method and experimental verification.” The International Journal of Advanced Manufacturing Technology 114, 2447–2455.

Downloads

Published

2023-12-01

How to Cite

[1]
J. SLN, Murali Krishna N L, and Raju H P, “EVALUATION OF INDUCED SURFACE INTEGRITY IN EXTRUSION HONING PROCESS ”, JME, vol. 18, no. 4, pp. 118–129, Dec. 2023.