Simulation and study of polishing of special curvature based forging die by using abrasive flow machining

Nowadays in different industries, researchers perform many attempts to reduce manpower because it is time consuming and needs high cost, high skill, and involves more human error. For this reason, for eliminating of the manual finishing, this article investigates finishing of special curvature based forging die manufactured by EDM process, the finishing process is performed by abrasive flow machining. These dies usually are finished manually. Abrasive flow machining is used for polishing of points of workpiece, which are in the direction of abrasive flow. This is the reason that, for flow distribution in die curvature an intermediate piece is used in other to provide a passage. Two phase simulation(fluid/solid) of flow in two dimensions shows that the total pressure at each point in complete cycle (piston stroke) is equal to a constant value since a direct relation exists between the amount of material removal in the process and the pressure amount, a uniform polishing could be expected. Performed experiments assert correctness of simulation. Empirical tests showed that the abrasive grain size is larger, the material removal rate is also higher. Also, by increasing the number of courses and concentrations of abrasive, material removal rate is also increasing. Dimensional accuracy has been maintained in this process.