Evaluation and optimization of complex inner hole structure in abrasive flow machining
To improve the reliability and machining quality of deburring process for inner holes of projectile components, an evaluation index for the quality of inner hole abrasive flow machining (AFM) is established based on the inverted fillet radius, material removal rate, and surface roughness. An orthogonal test was designed and completed, with abrasive particle size, abrasive mass fraction, abrasive flow working pressure, and cycle numbers as the control factors. Results indicate that all process parameters can ensure good deburring effect. The working pressure of AFM is the primary and significant influencing factor on the inverted filler radius. The primary influencing factor on the material removal rate is the abrasive mass fraction. And for surface roughness, it is cycle numbers. Furthermore, A prediction model for process parameters and machining quality evaluation indexes was established through nonlinear regression analysis. Multi-objective optimization was performed using the fast elitist non-dominated sorting genetic algorithm (NSGA-Ⅱ). The optimized parameters (The abrasive grain size is 1000#, the mass fraction of abrasive is 40％, the pressure is 7.5 MPa, and cycles times is 30) were verified and the optimized results are consistent with the actual machining.
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