A critical review of past research and advances in abrasive flow finishing process

Abstract

Abrasive flow finishing (AFF) is an advanced nano-finishing process using abrasive-laden self-deformable putty for finishing, deburring, radiusing, chamfering, stress-relieving, and mirror-like polishing of the complicated components and inaccessible areas which are difficult or impossible to finish by other processes. Since its inception during 1950s, continuous research and advances in AFF are being reported globally. This paper presents comprehensive and critical review of the past research and developments on process modeling, rheological characterization of the AFF medium, development of finishing medium, development of various hybrid, derived, and hybrid-derived processes of AFF, and some novel applications of AFF for complicated shapes and difficult-to-finish materials. Major findings and observations, details of the workpiece material, finishing medium, process parameters, and responses have been presented in a tabular format for quick reference. It also covers some novel applications of AFF in the field of avionics, automobiles, biomedical, gears, additive manufacturing, cutting tool inserts, die and mold manufacturing, and recast layer removal. Finishing results for various materials such as mild steel, brass, aluminum, and its alloys, tool steel, copper, metal matrix composite, and photopolymer resin are also included. It also identifies directions for future research and provides an invaluable list of literature on past research works on AFF process. This review article will be very useful for the researchers working in micro- and nano-finishing applications and the industries involved in manufacturing of the automobiles, aero-engines, avionics components, biomedical implants, gears, impellers, dies and molds, and defense equipment.