A Study of Abrasive Media Effect on Deburring in Barrel Finishing Process

Subject Areas :

Ali Vakili Sohrforozani ¹ , Masoud Farahnakian ² , Mohammad Mahdieh ³ , Amir Masoud Behagh ⁴ , Omid Behagh ⁵

1 - Department of Mechanical Engineering, Najafabad Branch, Islamic Azad University, Najafabad, Iran
2 - Department of Mechanical Engineering, Najafabad Branch, Islamic Azad University, Najafabad, Iran
3 - Department of Mechanical Engineering, Shahid Chamran University of Ahvaz, Ahvaz, Iran
4 - Arshan Sanat Jam Co. ltd, Isfahan, Iran
5 - Arshan Sanat Jam Co. ltd, Isfahan, Iran

Received: 2019-11-06 Accepted : 2020-01-27 Published : 2019-08-01

Keywords: Design of Experiments, Mass finishing, Barrel finishing, Deburring, Radiusing,

Abstract :

Formation of the burrs in the industrial parts after manufacturing processes such as blanking, punching, machining, cutting and etc. is inevitable. The burring phenomenon decreases the geometrical and dimensional tolerance and makes assembling parts together difficult. Radiusing the corners of workpieces is a common technique to reduce the stress concentrations at corners and also facilitate their assembly. By means of barrel finishing, a number of workpieces undergo deburring and radiusing coincidently in one process. In barrel finishing which is one of the mass finishing techniques, many workpieces with abrasive media are loaded in a rotary barrel. By rotation of the barrel, the parts and abrasive media are collided to each other and rub themselves, resulting in deburring and polishing the workpieces. The working time of this process is normally long. The aim of this study is to decrease the working time by using proper abrasive media. Here, a number of experiments is designed on combination of three abrasive media: steel balls, ceramics and aluminum oxide particles, in different working periods, to achieve appropriate radius and reducing burrs height of CK45 steel alloy samples in reduced working time.

References:

[1] Mahdieh, M.S. and Mahdavinejad, R. 2016. Recast layer and micro-cracks in electrical discharge machining of ultra-fine-grained aluminum. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 0954405416641326.

[2] Mahdieh, M.S. and Mahdavinejad, R.A. A study of stored energy in ultra-fined grained aluminum machined by electrical discharge machining. 2016. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science. 0954406216666872.

[3] Mahdieh, M.S. 2019. Recast layer and heat-affected zone structure of ultra-fined grained low-carbon steel machined by electrical discharge machining. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 0954405419889202.

[4] Mahdieh, M.S. and Mahdavinejad, R. 2016. Comparative Study on Electrical Discharge Machining of Ultrafine-Grain Al, Cu, and Steel. Metallurgical and Materials Transactions A. 47:6237–6247.

[5] Mahdieh, M.S. and Zare-Reisabadi, S. 2019. Effects of electro-discharge machining process on ultra-fined grain copper. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science. 0954406219844802.

[6] Mahdieh, M.S. 2020. The surface integrity of ultra-fine grain steel, Electrical discharge machined using Iso-pulse and resistance–capacitance-type generator. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications.1464420720902782.

[7] Mahdieh, M.S., Rafati, E., and Sichani, S.K. 2013. Investigation of Variance of Roller Burnishing Parameters on Surface Quality by Taguchi Approach. International Journal of Advanced Design and Manufacturing Technology. 6(3):77-81.

[8] Boschetto, A., Ruggiero, A. and Veniali, F. 2006. Corner shaping by barrel finishing. ASME 8th Biennial Conference on Engineering Systems Design and Analysis. American Society of Mechanical Engineers. Paper No: ESDA2006-95683:877-881.

[9] Saraeian, P., Gholami, M., Behagh, A., Behagh, O., Javadinejad, H. R. and Mahdieh, M. S. 2016. The Influence of Vibratory Finishing Process by Incorporating Abrasive Ceramics and Glassy Materials on the Surface Roughness of CK45 Steel. International Journal of Advanced Design and Manufacturing Technology. 9(4):1-6.

[10] Boschetto, A., Ruggiero, A. and Veniali, F. 2007. Deburring of sheet metal by barrel finishing. Key Engineering Materials. 344:193-200.

[11] Bottini, L., Boschetto, A. and Veniali, F. 2014. Estimation of Material Removal by Profilometer Measurements in Mass Finishing. Key Engineering Materials. 611-612: 615-622.

[12] Boschetto, A., Bottini, L. and Veniali, F. 2013. Microremoval modeling of surface roughness in barrel finishing. The International Journal of Advanced Manufacturing Technology. 69(9-12):2343-2354.

[13] Li, W.H., Yang, S.Q. and Yang, S.C. 2008. Theoretic Analysis and Experimental Research on Barrel Finishing Uniformity of Crank Shafts with Larger Size. in Key Engineering Materials. Trans Tech Publ. 852: 573-577.

[14] Li, W. H., Yang S. C., Yang S. Q., and Chen, H.L. 2008. Process Characteristics Research on Horizontal Spindle Barrel Finishing. in Advanced Materials Research. 53-54: 15-19.

[15] Li, W.H., Chen, H. and Yang, S.Q. 2009. Surface Integrity Research on Barrel Finishing of Crankshafts’ Part.. Key Engineering Materials. 392-394: 655-660.

[16] Li, W.H., Yang, S.Q., Yang, S.C. and Chen, H. 2009. Theoretic Analysis and Simulation on Horizontal Spindle Barrel Finishing. Key Engineering Materials. 416: 332-336.

[17] Li, W.H., Yang, S.Q, Yang, S.C. and Chen, H. 2010. Research of Uniformity and Effect on Crankshaft Barrel Finishing. Advanced Materials Research. 97-101: 4120-4123.

[18] Nityanand, N., Manley, B. and Henein, H. 1986. An analysis of radial segregation for different sized spherical solids in rotary cylinders. Metallurgical Transactions B. 17(2): 247-257.

[19] Boschetto, A. and Veniali, F. Radial segregation of workpiece in barrel finishing. 2002. AMST’02 Advanced Manufacturing Systems and Technology, Proceedings of the 6th International Conference. 499-505.

[20] Mellmann, J. 2001.The transverse motion of solids in rotating cylinders—forms of motion and transition behavior. Powder Technology. 118(3): 251-270.

[21] Boateng, A. 1998.  Boundary layer modeling of granular flow in the transverse plane of a partially filled rotating cylinder. International Journal of Multiphase Flow. 24(3): 499-521.

[22] Boschetto, A., Marchetti, E. and Veniali, F. 2001. Analysis of the charge movements in barrel finishing. Engineering. Technology Conference on Energy. 69: 2343–2354.

[23] Cantelaube, F., Bideau, D. and Roux, S. 1997. Kinetics of segregation of granular media in a two-dimensional rotating drum. Powder technology. 93(1):1-11.

[24] Parker, D.J., Dijkstra, A.E., Martin, T.W. and Seville, P.K. 1997. Positron emission particle tracking studies of spherical particle motion in rotating drums. Chemical Engineering Science. 52(13): 2011-2022.

[25] Bbosa, L.S., Govendera, I., Mainza, A.N., and Powell, M.S. 2011. Power draw estimations in experimental tumbling mills using PEPT. Minerals Engineering. 24(3):319-324.

[26] VanPuyvelde D.R., Young, B.R., Wilson, M.A. and Schmidt, S.J. 1999. Experimental determination of transverse mixing kinetics in a rolling drum by image analysis. Powder Technology. 106(3): p. 183-191.

[27] Nakagawa, M., Altobelli, S. A., Caprihan, A. and Fukushima, E. 1997. NMRI study: asial migration of radially segregated core of granular mixtures in a horizontal rotating cylinder. Chemical Engineering Science. 52(23):4423-4428.

[28] Boschetto, A. and Veniali, F. 2009. Workpiece and media tracking in barrel finishing. International Journal of Machining and Machinability of Materials. 6(3-4):305-321.

[29] Boschetto, A., Veniali, F. and Miani, F. 2004. Mass Finishing of Parts Produced by Direct Metal Laser Sintering. ASME 7th Biennial Conference on Engineering Systems Design and Analysis. American Society of Mechanical Engineers.

[30] Ding, Y., Seville, J.P.K.,  Forster, R. and Parker, D.J. 2001. Solids motion in rolling mode rotating drums operated at low to medium rotational speeds. Chemical Engineering Science. 56(5):1769-1780.

[31] Boateng, A. and Barr, P. 1996. Modelling of particle mixing and segregation in the transverse plane of a rotary kiln. Chemical Engineering Science. 51(17):4167-4181.

[32] Henein, H., Brimacombe, J. and Watkinson, A. 1983. Experimental study of transverse bed motion in rotary kilns. Metallurgical transactions B. 14(2):191-205.

[33] Chiancola, M. 1995. Choosing the right media to meet mass finishing goals. Metal Finishing. 93(12):37-39.