Abrasive Flow Machining

Process Principle, Parameters and

Capabilities
 Process Principle
• AFM is a finishing process that removes a
small quantity of material.
• It uses semi-solid, abrasive laden putty
through or across a work piece.
• It extruded across edges or surfaces to deburr,
radius, polish, remove recast, perform mirror
surface machining.
• A hydraulic ram forces the abrasive medium
through the work piece.
• As abrasive medium flows through the part,
its velocity will change with the different cross
– sectional areas.
• Due to its low MRR, it is not suited for mass
material removal.
• It is used for finishing in metals, ceramics, and
many plastics in uniform and economical
manner.
 Classification of AFM
• AFM is classified into three categories viz.
– One way AFM
– Two way AFM
– Orbital AFM
 Equipments
• Machine
– It is constructed with two opposing medium
chambers that are hydraulically or manually
clamped together.
– The pressure for extruding medium ranges from
0.69 to 22 MPa (100 to 3200 psi)
– Lower pressure preferred for fragile parts or loose
fixtures.
– Little heat is generated due to friction hence
medium coolants are recommended.
• Tooling
– Uses only to hold the part or parts in position.
– To contain and direct the flow of abrasives.
– Any number of parallel restrictions can be
processed with uniform results.
– Replaceable inserts made of nylon, Teflon or
hardened steel are used. Can last for up to
thousands of parts.
• Media
– AFM media is pliable material that is resilient
enough to act as a self forming grinding stone
when forced through restrictions.
• Media contains base and typically two or
three abrasive grit sizes.
• Base contains an organic polymer, specially
hydrocarbon gels; it determines the degree of
stiffness.
• Four types of abrasive are commonly used viz.
Aluminum oxide, silicon carbide, boron carbide and
diamond.
• Abrasives are available in grit sizes ranging
from 8 to 700 meshes.
 Process Parameters
• Flow Rate – 11.3 to 378 L/min. (3 – 100 GPM)

• Cycles – 3 to several hundred

• Pressure – 0.69 – 22 MPa (100 – 3200 psi)

 Process Capabilities
• AFM is able to increase surface smoothness
up to 10 times.
• The limit for best surface finish is 0.05
microns.
• Large surface irregularities like deep scratches
or large bumps cant be removed.
• Out of roundness and taper cant be corrected.
• Holes must be of dia. at least 0.2 mm for
effective processing.
 Process Summary
• Advantages
– Debur, polish, and radius in one operation
– More repeatable than manual method
– Finish inaccessible area
– Batch production
– Faster than manual
• Disadvantages
– Fixtures can be expensive
– High capital investment
– Cant process blind holes.