A Review on Abrasive Flow Machining (AFM)

Kumar, Surender; Hiremath, Somashekhar S.

doi:10.1016/j.protcy.2016.08.224

Cited by 85 publications

(30 citation statements)

References 32 publications

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“…However, it is often impossible to machine, or mechanically polish, a complex AM build due to limited accessibility, particularly for internal surfaces. Although alternative abrasive and chemical methods are being investigated, these all suffer from additional problems such as a lack of precision and shadowing [18,19]. Therefore, it is important to explore more controlled approaches to achieve a satisfactory surface finish.…”

Section: Introductionmentioning

confidence: 99%

Material interactions in laser polishing powder bed additive manufactured Ti6Al4V components

Tian

Góra

Cabo

et al. 2018

Additive Manufacturing

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Laser polishing (LP) is an emerging technique with the potential to be used for post-build, or in-situ, precision smoothing of rough fatigue-initiation prone surfaces of additive manufactured (AM) components. LP uses a laser to re-melt a thin surface layer and smooths the surface by exploiting surface tension effects in the melt pool. However, rapid resolidification of the melted surface layer and the associated substrate thermal exposure can significantly modify the subsurface material. This study has used an electron beam melted (EBM) Ti6Al4V component, representing the worst case scenario in terms of roughness for a powder bed process, as an example to investigate these issues and evaluate the capability of the LP technique for improving the surface quality of AM parts. Experiments have shown that the surface roughness can be reduced to below Sa=0.51 µm, which is comparable to a CNC machined surface, and high stress concentrating defects inherited from the AM process were removed by LP. However, the re-melted layer underwent a change in texture, grain structure, and a martensitic transformation, which was subsequently tempered in-situ by repeated beam rastering and resulted in a small increase in sub-surface hardness. In addition, a high level of near-surface tensile residual stresses was generated by the process, although they could be relaxed to near zero by a standard stress relief heat treatment.

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Section: Introductionmentioning

confidence: 99%

Material interactions in laser polishing powder bed additive manufactured Ti6Al4V components

Tian

Góra

Cabo

et al. 2018

Additive Manufacturing

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“…Many researchers have tried to develop alternative abrasive paste or semi-solid media apart from commercially available media and to study the media characterization [18]. Table 1 shows the development of the abrasive media by various researchers.…”

Section: Abrasive Suspension Slurrymentioning

confidence: 99%

“…Bai [17] developed a numerical model of common rail injector using bond graph methodology to predict the fuel injection quality of system accurately. Santhosh [18] reviewed several published technical papers on AFM with respect to its abrasive media and applications. Kenda [19], Wang [20], Kar [21], Sankar [22], and Guo [23] studied the rheological properties and the finishing behavior of abrasive medium in AFM through different examples.…”

Section: Introductionmentioning

confidence: 99%

An experimental investigation of abrasive suspension flow machining of injector nozzle based on orthogonal test design

Fang

2020

Int J Adv Manuf Technol

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The application of abrasive suspension flow machining (ASFM) to grind a diesel engine injector nozzle is discussed in this paper. The purpose is to remove the sharp corners of the spray holes and improve the fuel flow through the injector nozzle. The proposed method adopts one-way flow to grind the spray holes for high-efficiency production. Compared with traditional reciprocating flow grinding methods using abrasive pastes, the viscosity of slurry and abrasive concentration of ASFM are lower, better for more smooth flow. To achieve a good grinding performance, it is important to determine proper viscosity and concentration. For this purpose, a design of experiments (DoE) method is adopted. In this paper, an orthogonal test method is combined with a nonlinear regression method to optimize the process parameters. Through a range analysis on experiment results, the optimal process conditions in terms of the grinding efficiency and the grinding quality are determined. Experiment verifications show that the optimized process parameters can significantly improve the ASFM grinding efficiency and grinding quality.

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“…Therefore, the traditional finishing process is incapable of fulfilling such requirement of the die surface. To fix the problems such as flexibility in the process for finishing the various shapes of the workpieces, abrasive flow machining (AFM) and rotational abrasive flow finishing (R-AFF) are developed [3,4]. But still, these processes are associated with the problems like controllability of the finishing forces.…”

Section: Introductionmentioning

confidence: 99%

Experimental analysis of magnetorheological finishing of blind hole surfaces using permanent magnet designed tools

Sirwal

Singh

Paswan

2020

J Braz. Soc. Mech. Sci. Eng.

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Permanent mould dies are used for various plastic injection moulding products. Most of the mould cavity is blind and henceforth difficult to finish. In this study, a novel magnetorheological fluid-based finishing process using permanent magnet tools has been developed for nano-finishing of cylindrical blind hole surfaces. Tools to finish the internal and flat-bottomed surfaces of the cylindrical blind hole are developed. The finishing performance of both tools is evaluated for finishing ferromagnetic material used in dies. The material of the die is P20 tool steel having 41 HRC hardness. Response surface methodology using a central composite design technique has been utilized for the plan of experiments and analysis of significant process parameters on the percentage change in surface roughness using newly developed tools. During finishing the internal cylindrical blind hole surface, the process parameters like rotational speed, reciprocation speed and abrasive mesh size are found to be significant. However, during flat-bottomed surface finishing of cylindrical blind hole workpiece, rotational speed, abrasive mesh size and abrasives volume percentage are found to process significant parameters. Experimentation at optimized parameters results in the final surface finish of 83 nm on internal cylindrical surface and 93 nm on the flat-bottomed surface of cylindrical blind hole workpiece.

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A Review on Abrasive Flow Machining (AFM)

Cited by 85 publications

References 32 publications

Material interactions in laser polishing powder bed additive manufactured Ti6Al4V components

Material interactions in laser polishing powder bed additive manufactured Ti6Al4V components

An experimental investigation of abrasive suspension flow machining of injector nozzle based on orthogonal test design

Experimental analysis of magnetorheological finishing of blind hole surfaces using permanent magnet designed tools

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