A new predictive method of the finished surface profile in abrasive flow machining process

Abstract

In order to improve the functional surface finish of high performance and complex parts in high-end manufacturing industries, abrasive flow machining (AFM) taking semi-solid abrasive media as a finishing tool was proposed to enhance the accessibility of the finishing process. Owing to the complicated flow field of abrasive media in constrained passages, it is difficult to predict the finished surface profile of a functional surface after AFM processing. In this investigation, a novel prediction method combining numerical simulation and experiment was proposed with the analyses of material removal conducted for single, and multiple, particles. On this basis, the distributions of material removal and abrasive scratches were expounded in one-way AFM and two-way AFM processes with two kinds of constrained passages, it is believed that a high p∘v distribution and turbulent flow field produced by contraction section of inlet region of flow passage are the main reasons for the high material removal and irregular finishing marks at the inlet/outlet regions. Finally, verification experiments on the finishing of an aero-engine blade were carried out, a preferable constrained passage was obtained using this new prediction method and near-uniform material removal was observed. This work aims to establish a preferable prediction method for the whole surface profile finished by AFM process and provide fundamental guidance for the optimal design of constrained surfaces of complex components.