DEVELOPMENT OF THE SET-UP AND STUDY OF PROCESS CHARACTERISTICS OF ABRASIVE FLOW MACHINING

Abstract

Finishing operations in the metal working industry represent a critical and expensive phase of the overall production process. A new process called Abrasive Flow Machining (AFM) promises to provide the accuracy, efficiency, economy, and possibility of effective automation needed by the manufacturing community. Abrasive Flow Machining (AFM) is a nontraditional finish machining process that is used to deburr, polish, radius, remove recast layers or produce compressive residual stresses, AFM provides uniform, repeatable and predictable results. It can process many areas on a single workpiece or multiple parts simultaneously and complex internal passages can be finished economically and productively. AFM process is still in its infancy in many respects. The process mechanism, parametric relationships and surface integrity issues have not been effectively addressed. AFM involves equipment of moderately high cost; and expensive fixturing and proper media selection is critical to process most parts effectively. This dissertation reports the development of an AFM setup and the results of a study into some aspects of AFM process characteristics; and surface characterization using an indigneous —^ -- t~ media. The effect of process input parameters (such as number of AFM cycles; grit-size; abrasive concentration; and passage diameter) on the process performance characteristics (metal removal and percent surface finish improvement) are discussed. Scanning Electron Microscope (SEM) photographs of the surfaces indicate that "smear" does not. take place but the surface improvement is due to "shear ng' iiot ton and the microchips do form in the process.