Fine finishing of internal surfaces using elastic abrasives

• A unique approach of using abrasive-embedded-elastomeric spheres, referred as elastic abrasives, for micro/nano-finishing of internal surfaces is presented.
• Simple and cost effective experimental setup is introduced and the capability of the process is demonstrated through experimental results.
• Detailed experimental study and response surface analysis is reported to understand the effect of process variables.
• A mathematical model is presented to predict the material removal in the proposed approach.

The paper describes a simple and innovative approach of using elastic abrasives for generating ultra fine finish on internal surfaces of tubular specimens. Elastic abrasive is a unique concept of using abrasive embedded elastomeric balls having the special capability to deform in conformity to work surface and thereby imparting a very fine refinement of its profile without altering the form. The mechanism of material removal in the proposed methodology is analysed using a mathematical model and its validation was done using a systematic experimentation procedure. Response surface methodology using central composite design is applied for the experimental study to investigate the effect of axial pressure, abrasive grain size and longitudinal stroke velocity of elastic abrasives on the surface finish. The process discussed in this paper is a simple and cost effective option to produce micro/nano-finish on the internal surfaces of a wide range of industrial components including hollow specimens, high aspect ratio bores and sleeves.