ABRASIVE FLOW FINISHING OF FDM PRINTED EXTRUSION DIE INSERT PATTERN USING NOVEL AFM FIXTURE WITH MANDREL GUIDE

Abdul Wahab Hashmi, Harlal Singh Mali, Anoj Meena, Nakul Gupta, Shadab Ahmad, Kuldeep K. Saxena and Vinayak Malik
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Abdul Wahab Hashmi: Advanced Manufacturing and Mechatronics Lab, Department of Mechanical Engineering, Malaviya National Institute of Technology, Jaipur 302017, India
Harlal Singh Mali: Advanced Manufacturing and Mechatronics Lab, Department of Mechanical Engineering, Malaviya National Institute of Technology, Jaipur 302017, India
Anoj Meena: Advanced Manufacturing and Mechatronics Lab, Department of Mechanical Engineering, Malaviya National Institute of Technology, Jaipur 302017, India
Nakul Gupta: ��Department of Civil Engineering, GLA University, Mathura, UP 281406, India
Shadab Ahmad: ��School of Mechanical Engineering, Shandong University of Technology, Zibo 255000, P. R. China
Kuldeep K. Saxena: �Division of Research and Development, Lovely Professional University, Phagwara 144411, India
Vinayak Malik: �Department of Mechanical Engineering, KLS Gogte Institute of Technology, Belagavi 590008, Karnataka, India∥Department of Mechanical Engineering, Visvesvaraya Technology University, Belagavi 590018, Karnataka, India

Surface Review and Letters (SRL), 2023, vol. 30, issue 06, 1-26

Abstract: The staircase/stair-stepping effect causes wrapping, shrinkage, and surface roughness in additively manufactured (AM) parts. Consequently, abrasive flow finishing (AFF) or abrasive flow machining (AFM) may be employed to improve the AM part surface finish. This study developed an environmentally friendly AFM media using rice husk ash as base material, waste vegetable oil as a liquid synthesizer, and natural additives, i.e. glycerin. The new newly developed rice husk ash-based AFM media (HSAFM) characterization was done using Fourier Transform Infrared (FTIR) spectroscopic method and thermogravimetric analysis (TGA). AFM medium viscosity was optimized using a Taguchi design (L9). These FDM-printed extrusions die inserts were finished using optimized AFM media in a one-way AFM system. A new AFM fixture with a mandrel guide was developed to direct media flow inside the die cavity to ensure uniform finishing. Experimental research has been done on finishing the FDM-printed extrusion die insert pattern using the Box–Behnken Design (BBD)-based experimental design of the response surface methodology (RSM) technique. The surface roughness Ra Δ28.16 μm was improved by 96% with the following process parameters: media viscosity of 60 Pa/s, the layer thickness of 0.3, and 90 min of finishing time.

Keywords: Additively manufactured (AM); abrasive flow machining (AFM); rice husk ash-based AFM media (HSAFM); waste vegetable oil; rheological test; FTIR; TGA; FDM parts; etc (search for similar items in EconPapers)
Date: 2023
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DOI: 10.1142/S0218625X23500348

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