Abstract
Abrasive flow finishing (AFF) is an advanced finishing process employed for finishing macro- to micro-features of workpieces. Finishing improves the functioning of the components by reducing their surface roughness. AFF process uses a polymer-based flexible medium containing abrasive particles as a finishing tool. Medium used during the AFF process plays a vital role in deciding the final surface roughness on the workpiece surface. It is the medium properties in combination with AFF input parameters that decide the end surface roughness. Micro-features on the components are mostly machined with the help of processes involving thermal energy (electrical discharge micro-machining, laser beam micro-machining). This leads to the formation of hard recast layer on the micro-machined workpiece surface. Component size and hardness of the recast layer possesses a great challenge to the finishing processes. In the current article, an economic viscoelastic medium is developed for the finishing of micro-features and its detailed rheological study is carried out. Later, experimental study of the AFF process during the finishing of micro-slots (440 ± 10 µm width) in surgical steel is performed. Developed medium successfully finishes the micro-slots with an initial surface roughness of 3.54 µm to a final surface roughness of 0.21 µm (94.07% reduction in surface roughness).
Published Version
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