A digital process optimization, process design and process informatics system for high-energy abrasive mass finishing

This research describes a new digital-based system to improve the efficiency and to reduce costs of high-energy abrasive mass finishing processes. The system is developed from a rigorous programme of theoretical analyses, technical experiments and industry validations. The system is able to predict the response of the process, in the context of component surface roughness and cycle time, due to employed input parameters: machining speeds, rotational velocities, immersion depth and abrasive media type. A graphical user interface (GUI) was designed to permit on-screen analyses and determination of system response under a wide range of parameters. The system converges to an optimized machining solution using optimization methods and convergence theory. The output from the system associates optimized machining parameters with output criteria that may be a target surface roughness, a minimum cycle time or a production planning period. This facilitates use of the system as a cycle design tool, as production decision support or as a process cost model. The system is generic in design and with minor modification of input and output criteria and has potential application to many other processes and applications including for example, pharmaceutical, food processing, agriculture and automotive.