Title: Sizing and finishing of non-circular internal bores using elasto-abrasives

Authors: V.S. Sooraj; V. Radhakrishnan

Addresses: Department of Aerospace Engineering, Indian Institute of Space Science and Technology (IIST), Valiamala, Trivandrum, Kerala – 695547, India ' Department of Aerospace Engineering, Indian Institute of Space Science and Technology (IIST), Valiamala, Trivandrum, Kerala – 695547, India

Abstract: Non-circular bores, typically cut with wire electric discharge machining, find extensive applications in industrial use. However sizing and fine-finishing of such internal surfaces, without altering its basic form, is a challenging task. Elasto-abrasive finishing is a recently introduced methodology, employing abrasive embedded elastomeric beads as the finishing medium. This paper discusses the application of elasto-abrasives in the form of meso-scale balls for progressive sizing and finishing of non-circular bores. Two types of elasto-abrasive balls with different elastomeric characteristics are introduced in this research, one for sizing cycle followed by the second for finishing. Processing of oval bores cut in hardened steel specimens, using Type II balls, yielded an average size variation of 10 µm in its radial dimensions without affecting the oval shape. The progressive processing of these specimens using Type I balls resulted in an average roughness of 0.03 µm, significantly reduced from its initial value of 0.2 µm.

Keywords: elasto-abrasives; fine finishing; sizing; surface roughness; bore finishing; abrasion; non-circular internal bores; surface quality; fine finishing; internal surfaces; elasto-abrasive finishing; elastomeric beads; oval bores; hardened steel.

DOI: 10.1504/IJPTECH.2015.073830

International Journal of Precision Technology, 2015 Vol.5 No.3/4, pp.261 - 276

Available online: 23 Dec 2015 *

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