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Dynamic Jamming in Dense Suspensions:
Surface Finishing and Edge Honing Applications
Joseph Span, Philip Koshy
McMaster University
Fritz Klocke, Sebastian Mueller
RWTH Aachen University
Reginaldo Coelho
University of Sao Paulo
1/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
Belmont
… surface finishing and edge honing
corn starch
Ideal for sauces, soups and puddings …
2/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
Belmont
Discovery Channel
3/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
Belmont
qedmrf
magnetorheological polishing
electrorheological polishing
Kuriyagawa et al (2002)
In the present work,
the interaction
between abrasives
and workpiece is
regulated by
controlling the
process kinematics
Crawford et al (2013)
4/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
Belmont
| cornstarch water systemShear thickening fluid
shear thinningequilibrium shear thickening
Wagner & Brady (2009)
5/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
Belmont
Shear thickening polishing
polymer water
Li et al (2015)
6/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
Belmont
strain rate 8 to 230 s-1
Finishing performance was proportional to the resultant force
on the coupon
cornstarch
7/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
Belmont
Hypothesis: surface finishing is due to dynamic jamming
rather than shear thickening
Waitukaitis
8/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
Belmont
Dynamic jamming refers to the
formation of a transient, localized,
solid-like domain in a suspension,
at packing densities well below that
required for global jamming
stop-go cycles
velocity(m/s)
time (s)
9/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
Belmont
molding clay
Liu et al (2010)
Kann et al (2013)
10/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
11/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
0
20
40
60
80
resultantforce(N)
couponboundary suspension
2 s
jammed domain
Surface finishing is indeed due to jamming
12/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
Jamming was initially attributed
to compression of the particles
(Waitukaitis, 2015)
Ultrasound imaging of the
jammed region has however
indicated no appreciable
increase in particle density
(Han et al, 2016)
Jamming occurs also
under extensional loading
(Majumdar et al, 2017)
Jamming by shear
(Bi, 2011)
13/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
strain rate
axial
radial
Velocity and strain rate distribution due to impact
velocity
Han et al (2016)
Peters & Jaeger (2014)
14/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
coupon
suspension
abrasive
Mechanism of material removal
On stopping the coupon, the stresses are insufficient to maintain frictional
contacts between particles, which collapses the load bearing network,
returning the suspension to its fluid-like state
cornstarch particle
Transient network of
force chains
transmit stresses
without an increase
in packing density
Stresses in the jammed
domain enable particles to
overcome viscous forces and
establish frictional contacts
Jamming front that
corresponds to the
maximum local
shear strain rate
15/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
Belmont
Introduction of abrasives
much larger in size than
the cornstarch particles
tends to structurally
interfere with their
consolidation into a
load-bearing network
Crawford et al (2013)
~15 µm
corn starch
size distribution
16/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
Belmont
Interaction of the jammed domain with a rigid boundary establishes
a solid-like link in-between, which translates into higher forces
Range of normal stresses are similar to that in magnetic
abrasive finishing
17/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
Belmont
Finishing performance of abrasive-cornstarch suspension
18/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
Application to edge honing of cutting tools
As the finishing medium closely conforms to the
shape of the object, the process may be applied
to finish, deburr, hone complex-shaped
surfaces, edges and tools
19/20
67th CIRP General Assembly
Lugano, August 22, 2017
Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications
J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
Belmont
Conclusions
Proof-of-concept of a novel process involving a dense aqueous
suspension of cornstarch for surface finishing and edge honing
The mechanism of material removal was shown to be related to
shear-induced, localized, dynamic jamming of the suspension
Parameters such as the translation speed, composition of the
medium and the influence of a rigid boundary on process forces
offer enhanced prospects for control and optimization
The finishing medium has the potential to augment productivity
in such processes as vibratory/drag finishing
RoslerWaitukaitis
Thank you
for your kind attention!
Natural Sciences & Engineering
Research Council of Canada
Canadian Network for
Research & Innovation in
Machining Technology

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Dynamic Jamming in Dense Suspensions: Machining Applications

  • 1. Dynamic Jamming in Dense Suspensions: Surface Finishing and Edge Honing Applications Joseph Span, Philip Koshy McMaster University Fritz Klocke, Sebastian Mueller RWTH Aachen University Reginaldo Coelho University of Sao Paulo
  • 2. 1/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho Belmont … surface finishing and edge honing corn starch Ideal for sauces, soups and puddings …
  • 3. 2/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho Belmont Discovery Channel
  • 4. 3/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho Belmont qedmrf magnetorheological polishing electrorheological polishing Kuriyagawa et al (2002) In the present work, the interaction between abrasives and workpiece is regulated by controlling the process kinematics
  • 5. Crawford et al (2013) 4/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho Belmont | cornstarch water systemShear thickening fluid shear thinningequilibrium shear thickening Wagner & Brady (2009)
  • 6. 5/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho Belmont Shear thickening polishing polymer water Li et al (2015)
  • 7. 6/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho Belmont strain rate 8 to 230 s-1 Finishing performance was proportional to the resultant force on the coupon cornstarch
  • 8. 7/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho Belmont Hypothesis: surface finishing is due to dynamic jamming rather than shear thickening Waitukaitis
  • 9. 8/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho Belmont Dynamic jamming refers to the formation of a transient, localized, solid-like domain in a suspension, at packing densities well below that required for global jamming
  • 10. stop-go cycles velocity(m/s) time (s) 9/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho Belmont molding clay Liu et al (2010) Kann et al (2013)
  • 11. 10/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho
  • 12. 11/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho 0 20 40 60 80 resultantforce(N) couponboundary suspension 2 s jammed domain Surface finishing is indeed due to jamming
  • 13. 12/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho Jamming was initially attributed to compression of the particles (Waitukaitis, 2015) Ultrasound imaging of the jammed region has however indicated no appreciable increase in particle density (Han et al, 2016) Jamming occurs also under extensional loading (Majumdar et al, 2017) Jamming by shear (Bi, 2011)
  • 14. 13/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho strain rate axial radial Velocity and strain rate distribution due to impact velocity Han et al (2016) Peters & Jaeger (2014)
  • 15. 14/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho coupon suspension abrasive Mechanism of material removal On stopping the coupon, the stresses are insufficient to maintain frictional contacts between particles, which collapses the load bearing network, returning the suspension to its fluid-like state cornstarch particle Transient network of force chains transmit stresses without an increase in packing density Stresses in the jammed domain enable particles to overcome viscous forces and establish frictional contacts Jamming front that corresponds to the maximum local shear strain rate
  • 16. 15/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho Belmont Introduction of abrasives much larger in size than the cornstarch particles tends to structurally interfere with their consolidation into a load-bearing network Crawford et al (2013) ~15 µm corn starch size distribution
  • 17. 16/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho Belmont Interaction of the jammed domain with a rigid boundary establishes a solid-like link in-between, which translates into higher forces Range of normal stresses are similar to that in magnetic abrasive finishing
  • 18. 17/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho Belmont Finishing performance of abrasive-cornstarch suspension
  • 19. 18/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho Application to edge honing of cutting tools As the finishing medium closely conforms to the shape of the object, the process may be applied to finish, deburr, hone complex-shaped surfaces, edges and tools
  • 20. 19/20 67th CIRP General Assembly Lugano, August 22, 2017 Dynamic Jamming in Dense Suspensions: Surface Finishing & Edge Honing Applications J. Span, P. Koshy, F. Klocke, S. Mueller, R. Coelho Belmont Conclusions Proof-of-concept of a novel process involving a dense aqueous suspension of cornstarch for surface finishing and edge honing The mechanism of material removal was shown to be related to shear-induced, localized, dynamic jamming of the suspension Parameters such as the translation speed, composition of the medium and the influence of a rigid boundary on process forces offer enhanced prospects for control and optimization The finishing medium has the potential to augment productivity in such processes as vibratory/drag finishing RoslerWaitukaitis
  • 21. Thank you for your kind attention! Natural Sciences & Engineering Research Council of Canada Canadian Network for Research & Innovation in Machining Technology