SOME STUDIES ON EFFECT OF PROCESS PARAMETERS ON PROCESS PERFORMANCE IN HYBRID ABRASIVE FLOW MACHINING

Abstract

Finish machining of precision components constitutes one of the most challenging and expensive stages in a manufacturing process. Abrasive flow machining (AFM) is a non-traditional machining technique that deburrs, polishes, and radiuses surfaces and edges by flowing an abrasive-laden media over these areas. The process is particularly used for internal shapes that are difficult to process by other non-conventional machining processes. The process embraces a wide range of applications from critical aerospace and medical components to high-production volumes, of parts. Low material removal rate happens to be one serious limitation of this process. To enhance the capabilities of conventional AFM process, a centrifugal force is imparted to the abrasive particles in the media. Thus, Centrifugal Force Assisted Abrasive Flow Machining (CFAAFM) is a hybrid machining process developed for better process performance. In the present work, a special tooling is fabricated for enhancement of surface finish and material removal. Casted Aluminum alloy (2014) was used as work piece material for studying the process parameters affecting on the process_ performance and their optimization. Statistical models were developed for surface finish and material removal. Various characterization techniques like FE-SEM, XRD and Stylus type profilometer were used for assessing the machined surface. Significant enhancement in surface finish and material removal were obtained with the CFAAFM process. 56.37% enhancement in surface finish and about 1.05% enhancement in material removal were recorded with the fabricated tooling system in the CFAAFM process. The process possesses high potential for application in mass production