Research PaperNo Access

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

Advanced Manufacturing and Mechatronics Lab, Department of Mechanical Engineering, Malaviya National Institute of Technology, Jaipur 302017, India

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HARLAL SINGH MALI

Advanced Manufacturing and Mechatronics Lab, Department of Mechanical Engineering, Malaviya National Institute of Technology, Jaipur 302017, India

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ANOJ MEENA

Advanced Manufacturing and Mechatronics Lab, Department of Mechanical Engineering, Malaviya National Institute of Technology, Jaipur 302017, India

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NAKUL GUPTA

Department of Civil Engineering, GLA University, Mathura, UP 281406, India

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SHADAB AHMAD

School of Mechanical Engineering, Shandong University of Technology, Zibo 255000, P. R. China

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KULDEEP K. SAXENA

https://orcid.org/0000-0003-4064-5113

Division of Research and Development, Lovely Professional University, Phagwara 144411, India

E-mail Address: [email protected]

Corresponding author.

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, and

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

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https://doi.org/10.1142/S0218625X23500348Cited by:8 (Source: Crossref)

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 ( $L_{9}$ ). 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 $Δ$ 28.16 $μ$ m 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:

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