Abrasive Flow Machining

Process Principle, Classification and Applications

 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.
 Abrasive is 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 manner.
 Abrasive Materials
 Abrasives
• Aluminum oxide
• Silicon carbide
• Boron carbide
• Diamond
 Polymeric medium
Viscoelastic polymer- shows
change in viscosity when under
pressure
 Abrasive grain size used in AFM
varies from 500 grit (tiny hole)
to 8 grit (stock removal and
stocking).
 Large abrasives are used to cut
faster.
 Small abrasives are used for
better surface finish as well as
they can reach narrow surfaces
easily.
 Classification of AFM

 AFM is classified into three categories viz.

1. One way AFM

2. Two way AFM
3. Orbital AFM
 One Way Abrasive Flow Machining
 One-way flow AFM processing
pushes abrasive media through
the work piece in only one
direction, allowing the media
to exit freely from the part.
 Advantages of One-way AFM
• Faster cycle processing
• Easy clean-up
• Media temperature control generally
not required
• Able to process larger parts
• Simpler tooling and part change-over
• Accurately replicates air or liquids
natural flow
 Two Way Abrasive Flow Machining
 Most widely used among the
three.
 The typical two-way flow AFM
process uses two vertically
opposed cylinders to extrude an
abrasive media back and forth
through or around passages
formed by the workpiece and
tooling. Abrasive action occurs
wherever the media enters and
passes through the most
restrictive passages
 Advantages of Two-way AFM
• Excellent process control
• Can finish both ID and OD of
component
• Good control of radius generation
• Fully automated system
capabilities
• Faster setup & quick-change
tooling
• Faster change-over of media
 Orbital Abrasive Flow Machining
 Surface and edge finishing are achieved
by rapid, low amplitude, oscillations of
the work piece relative to a self forming
elastic plastic abrasive polishing tool.
 The tool is a pad or layer of abrasive-
laden elastic plastic medium (similar to
that used in two way abrasive flow
finishing), but typically higher in
viscosity and more in elastic.
 Advantages of Orbital AFM
 Faster cycle processing
 Excellent process control
 Excellent surface finish for complex
inner surfaces
Disadvantages of Abrasive Flow Machining
 Low Material Removal Rate
 High Cost
(i) High Setup Cost
(ii) High Cost of Abrasive Medium
 Applications
 Aerospace industry
• Improved surface quality
• Enhanced cycle fatigue strength
• Optimized combustion and hydraulics
• Increased airflow
• Extended component life
 Medical Industry
• Eliminate the surface
imperfections where dangerous
contaminates can
reside
• Improved functionality,
durability and reliability of
medicalcomponents
• Enhanced uniformity and
cleanliness of surfaces,
• Extended component life
Thank You