Hand and abrasive flow polished tungsten carbide die: optimization of surface roughness, polishing time and comparative analysis in wire drawing

Raman Kumar, Sehijpal Singh, Vivek Aggarwal, Sunpreet Singh, Danil Yurievich Pimenov, Khaled Giasin, Krzysztof Nadolny

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Abstract

This research work highlights the benefits of abrasive flow polishing (AFP) applied to tungsten carbide dies compared with conventional hand polishing (HP). An indigenous experimental set-up for AFP was developed. The effect of prominent process parameters viz. extrusion pressure, number of cycles, and abrasive particle concentration on the final surface roughness, percentage improvement in surface roughness, and polishing time was investigated by Taguchi-designed experiments. The multi-objective optimization (MOO) was performed using the Taguchi-TOPSIS-Equal weight approach to find the respective optimized AFP parametric settings. A set of skilled operators performed the conventional HP of dies, and the best hand-polished (HPed) die was selected using the TOPSIS technique. The operational performance of the HPed dies and the abrasive flow polished (AFPed) dies were compared on the three-stage wire drawing operation. The results revealed that AFP’s surface resulted in a better-quality surface than hand polishing with a 27.06% improvement in surface roughness. Furthermore, AFP can reduce the dependency on costly and tricky-to-locate skilled operators, with a reasonable amount of time saving (about 87.05%). Overall, the study’s findings show that abrasive flow polishing of dies is fast and cost-effective.
Original languageEnglish
Article number1287
Number of pages21
JournalMaterials
Volume15
Issue number4
DOIs
Publication statusPublished - 9 Feb 2022

Keywords

  • abrasive flow polishing
  • hand polishing
  • surface roughness
  • wire drawing die
  • tungsten carbide
  • TOPSIS
  • polishing time
  • abrasive flow machining

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