Sample position inside abrasive fluidized bed to obtain morphology uniformity

Abrasive fluidized bed (AFB) machining of aluminum samples was studied with a specific focus on surface roughness formation, according to the sample position inside AFB operating in a minimum fluidization regime. The experimentation was aimed at defining optimum process conditions in terms of morphology uniformity and developing a mathematical model which relates the sample position to the final roughness. Measurements performed by profilometry have shown that a uniform average roughness lower than 1 μm can be obtained, starting from 3.5 μm, when the process parameters and handling are optimized. The analysis of variance (ANOVA) was performed to support the experimental and modeling strategy. This study led to the definition of a rapid and efficient procedure for finding the optimal positioning of samples in terms of finishing and surface uniformity. The proposed procedure does not require complex systems for component movement, and it is based on the study of just two reference positions of samples. The advantage of the procedure developed and validated in this study consists in its ease of implementation and its applicability in industrial strategies, where short decision times are essential.