EVALUATION OF RHEOLOGICAL PROPERTIES OF MEDIUM FOR AFM PROCESS

Abstract

Abrasive Flow Machining (AFM) is a new non-traditional machining process used to deburr, radius, polish, and remove recast layer of components used in a wide range of applications. Material removal in AFM takes place by flowing medium (i.e. carrier/or putty mixed with abrasive particles), across the surface to be machined. The medium is the key element in the process because of its ability to precisely abrade the selected areas along its flow path. From the literature review, it is found that there is a need to study how to evaluate rheological properties of the medium in general, and viscosity in particular. Viscosity of the medium has significant effects on the AFM process performance. In the present work, effects of concentration and mesh size of abrasive particles, and temperature of medium on the medium viscosity have been studied. To determine the viscosity of the abrasive medium, a viscometer has been designed and fabricated based on the principle of capillary viscometry. Experiments have been conducted at different abrasive concentrations and mesh sizes, and medium temperatures. It is observed from the experiments that the viscosity of the medium increases with the abrasive concentration and decreases with the abrasive mesh size and medium temperature. Theoretical values obtained from mathematical model, and experimental results are compared. The results of viscosity are correlated with the process performance parameters, i.e. material removal and surface roughness. It is observed that there is an increase in material removal and decrease in surface roughness value as viscosity of the medium increases.