Developing a Process Model for Abrasive Flow Machining

Abstract

Abrasive flow machining (AFM) is a unique machining method used to achieve high surface quality on inner, difficult-to-access contours and on outside edges. Using AFM, it is possible to deburr complex shaped intersecting holes and to realize pre-defined edge rounding on any brittle or hard material. Moreover it is easy to integrate into an automated manufacturing environment. Reproducibility of results saves various time and cost consuming manual operations in industrial applications. However for an implementation in new applications costly and time-consuming preliminary investigations are required that have to be carried out by trained staff. Therefore the aim of recent research activities is to identify the fundamentals of the process, the functional correlations between setting parameters and work results. This paper presents an approach using a numerical simulation to develop a process model. Furthermore a model is introduced that describes the fundamental principles of the deburring process using AFM.

Characterization Of Deburring By Abrasive Flow Machining for AL6061

“…According to the study of Ulman, deburring by abrasive flow progresses in three major steps [19]. First, burrs are forced to bend in one or two directions and cracks may initiate at the roots.…”

Modelling the abrasive flow machining process on advanced ceramic materials

“…A correlation between flow processes and surface formation on ceramic materials has not yet been discovered. In industry, the process is normally implemented in costly and time-consuming preliminary investigations that have to be carried out by trained staff (Uhlmann and Szulczynski, 2001). The aim of the research-project is to elaborate the fundamentals of the process and to detect functional correlations between setting parameters, process and work result.…”