Hardness Effects on Abrasive Flow Machining

Kursad Gov,Omer Eyercioglu,Mehmed Veysel Cakir

doi:10.5545/sv-jme.2013.1129

Kursad Gov, Omer Eyercioglu + Show 1 more

Open Access

https://doi.org/10.5545/sv-jme.2013.1129

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Abstract

Abrasive flow machining (AFM) is a manufacturing technique that uses the flow of a pressurized abrasive media to remove workpiece material. In comparison with other polishing technique, AFM is very efficient, suitable for the finishing of complex inner surfaces. In this paper, the effect of workpiece hardness on the AFM process has been investigated. An experimental study was carried out on AISI D2 tool steel hardened to 31, 45 and 55 HRC. The specimens were cut by using wire electro discharge machining (WEDM) and then finished with AFM. The results show that the white layer formed during WEDM is successfully removed by AFM in a few cycles. Although the surface quality is improved by AFM for all hardness groups, the results show that harder materials have more surface improvement than the softer ones.

Highlights

Abrasive flow machining (AFM) is a nontraditional machining process that was developed in the USA in the 1960s
During the wire EDM process, rapid heating and cooling occurs, and causes a heat-affected layer on the machined surface to form. This layer is generally formed by the sticking of the non-removed debris and the depth of material affected from high temperature
The white layer formed during wire electro discharge machining (WEDM) is successfully removed by AFM in a few cycles

Summary

Introduction

Abrasive flow machining (AFM) is a nontraditional machining process that was developed in the USA in the 1960s. AFM can be described as pressurized media passing through the surfaces to reach the desired surface quality. There are mainly two types of abrasive flow machines according to flow of media: one-way and two-way. The media consists of a type of polymeric carrier and abrasive particles that are SiC, Al2O3, diamond, etc. AFM is used to deburr, polish, radius, and remove recast layers. Applications of AFM include the finishing of extrusion dies, medical implants and aerospace components. With the use of AFM, excellent surface finishes and close geometric tolerances can be attained economically. The media in the AFM process is used to polish difficult-to-reach areas, and to follow complex geometries and microholes

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