Abstract
The abrasive flow machining (AFM) processes are ultra-precise finishing techniques widely used as finishing solutions for micro/nano finishing of inaccessible contours on difficult to machine components. The AFM processes use highly visco-elastic properties of the abrasive laden medium as a cutting tool for deburring, edge rounding and polishing the surface. Due to the design of workpiece holder and hybridization of basic AFM, the complex shear modulus of the abrasive laden medium can locally be influenced and thus a targeted removal of material from workpiece can be achieved, as a result, there was improved performance, productivity, surface integrity, and texture. This article addresses the detailed classification of AFM processes based on the use of different energy and tooling and highlights the critical outcomes in each category. The objective of this article is to review and summarize various process parameters of AFM processes like extrusion pressure, medium flow volume, medium flow rate, number of cycle, viscosity, workpiece geometry, etc. and their effects on roughness value and material removal rate. Key capabilities and noted findings concerning various AFM processes in addition to their applications and future challenges are also discussed in this paper.
Highlights
In the modern era, deterministic high precision finishing methods are of great importance and are the requirement of present manufacturing scenario due to their most critical, labor-intensive and highly uncontrollable nature
Various hybrid Abrasive flow machining (AFM) processes; CFAAFM, R-AFF, drill bit guided abrasive flow finishing (DBG-AFF), Magnetically assisted abrasive flow machining (MAAFM), ECAFM, and Ultrasonic assisted AFM (UAAFM) had been developed by various researchers
In the magnetorheological fluid based finishing (MRFF) process, the force acting on the individual abrasive particle was low and in R-Magneto-Rheological Abrasive Flow Finishing (MRAFF) process, the medium was viscoplastic and viscosity was quite low as compared to viscoelastic AFM medium
Summary
Deterministic high precision finishing methods are of great importance and are the requirement of present manufacturing scenario due to their most critical, labor-intensive and highly uncontrollable nature. The major problems associated with AFM process were low productivity rate, uncontrolled forces that affect the final surface finish and restrict its usage only to finish the internal surfaces To overcome these problems and have better abrasion with high finishing rate, AFM process has been hybridized with some other conventional/nonconventional machining processes [31,32,33,34,35]. Various hybrid AFM processes; CFAAFM, R-AFF, DBG-AFF, MAAFM, ECAFM, and UAAFM had been developed by various researchers These hybrid processes can be classified in two different ways; one in which all constituent processes were directly involved in the material removal and surface finish. The conventional ECM and ultrasonic machining assist the advanced AFM process for giving double cutting action Through these hybrid AFM processes, 50–80% improvement in surface roughness value was observed as compared to basic AFM. An attempt has been made to highlight the key capabilities of various AFM processes with cost efficiency analysis in addition to future trends
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