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Advanced Finishing Processes

This document discusses advanced finishing processes and focuses on abrasive flow machining (AFM). It describes AFM as a deburring process that uses abrasive grains mixed in a putty-like matrix to abrade surfaces. The document outlines different types of AFM including one-way, two-way, and orbital and discusses their mechanisms and advantages. It also covers AFM process parameters and applications in aerospace, automotive, die and mold making, and medical industries to achieve improved surfaces, tolerances, flows and extended component lifetimes.

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ADWAITH G S
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106 views23 pages

Advanced Finishing Processes

This document discusses advanced finishing processes and focuses on abrasive flow machining (AFM). It describes AFM as a deburring process that uses abrasive grains mixed in a putty-like matrix to abrade surfaces. The document outlines different types of AFM including one-way, two-way, and orbital and discusses their mechanisms and advantages. It also covers AFM process parameters and applications in aerospace, automotive, die and mold making, and medical industries to achieve improved surfaces, tolerances, flows and extended component lifetimes.

Uploaded by

ADWAITH G S
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Advanced Finishing Processes

Advanced Finishing Processes


(AFPs)
➢ Abrasive Flow Machining (AFM)
➢ Magnetic Abrasive Finishing (MAF)
➢ Magneto Rheological Finishing (MRF)
➢ Magneto Rheological Abrasive Flow Finishing
(MRAFF)
➢ Magnetic Float Polishing (MFP)
➢ Elastic Emission Machining (EEM)
➢ Ion Beam Machining (IBM)
➢ Chemical Mechanical polishing (CMP)
Abrasive Flow Machining

❖ It is basically used as a deburring process.


❖ Developed in 1960 by Extrude Hone Cooperation.
❖ AFM can
Polish and deburr parts internally
Polish through holes
Polish intersecting holes
Calibrate fuel injection nozzles to a specific flow rates
❖ Uses abrasive grains mixed in a putty (a form of cement) like matrix which
abrades the surface/burrs from the specific area of the material.
NEED
❖ Smooth surfaces – Aerospace and precision components

❖ High flow rates – Fluid dynamics and nozzles

❖ Torque and fuel economy – Fuel nozzles and engine components

❖ Eliminate the imperfections – Medical field


Abrasive Material
❖ Abrasives
Aluminum oxide
Silicon carbide
Boron carbide
Diamond
❖ Mixed in Polymeric medium
Viscoelastic polymer- shows change in viscosity when under pressure
Mechanism Of AFM

❖ Initially the material is ploughed by the fine


abrasives which come in contact with the work
material as it rub over the metal surface with
high pressure.
❖ The material flow occurs in the direction of the
motion of abrasive particles as well as in lateral
direction, resulting into the formation of the
chips.
❖ The further flow of abrasive particles causes
continued work hardening which results in
embrittlement and fragmentation of the chips
into micro chips.
Components of AFM
❖ Machine to control the process variables like extrusion pressure, medium flow
volume, and flow rate.
❖ Tooling which confines and directs the abrasive medium flow to the areas
where deburring, polishing and surface improvements are desired. It contains;
Workpiece
Fixture plate
Fixtures
Pumping device
❖ The abrasive laden Polymeric Medium whose rheological properties
determine the pattern and aggressiveness of the abrasive action.
Classification of AFM
❖ One way
❖ Two Way
❖ Orbital
One-way AFM
❖ One-way flow AFM processing pushes abrasive media through the work piece
in only one direction, allowing the media to exit freely from the part.
Advantages of One-way AFM
❖ Faster cycle processing
❖ Easy clean-up
❖ Media temperature control generally not required
❖ Able to process larger parts
❖ Simpler tooling and part change-over
❖ Accurately replicates air or liquids natural flow
❖ Does not encapsulate work-part in media
Two-way AFM
❖ Most widely used among the three.
❖ The typical two-way flow AFM process
uses two vertically opposed cylinders to
extrude an abrasive media back and
forth through or around passages
formed by the workpiece and tooling.
❖ Abrasive action occurs wherever the
media enters and passes through the
most restrictive passages
Two-way AFM
Advantages of Two-way AFM
❖ Excellent process control
❖ Can finish both ID and OD of component
❖ Good control of radius generation
❖ Fully automated system capabilities
❖ Faster setup & quick-change tooling
❖ Faster change-over of media
Orbital AFM
❖ Surface and edge finishing are achieved by rapid, low- amplitude,
oscillations of the work piece relative to a self- forming elastic plastic
abrasive polishing tool.
❖ The tool is a pad or layer of abrasive-laden elastic plastic medium (similar
to that used in two way abrasive flow finishing), but typically higher in
viscosity and more in elastic.

Before starting of finishing After starting of finishing


Machine Abrasive Workpiece

Extrusion pressure Medium viscosity Restricting


passage flow
Flow Volume and area
Abrasive
Concentration
Media flow speed
Abrasive Ductile/Brittle
type & size
Number of Cycles
AFM process parameters
Abrasive Based
❖ Abrasive grain size used in AFM varies from 500 grit (tiny hole) to 8 grit
(stock removal and stocking)
❖ Large abrasives- cut faster
❖ Small abrasives – better surface finish as well as they can reach narrow and
complex surfaces easily.
Machine Based
❖ Pressure - 0.7 Mpa to 22 Mpa (100 psi to 3200 psi)
Capabilities of AFM process
❖ Surface finish in the range of 28 to 280 μm.
❖ Hole of 0.2 mm can be made.
❖ Dimensional tolerances achievable upto ± 0.005mm.
❖ Can reduce surface roughness by 75 to 90% on cast, machined or EDM
sufaces.
Application
1. Aerospace industry

❖ Improved surface quality


❖ Enhanced cycle fatigue strength
❖ Optimized combustion and hydraulics
❖ Increased airflow
❖ Extended component life
Application
2. Automotive industry

❖ Enhanced uniformity and surface quality of finished components


❖ Increased engine performance
❖ Increased flow velocity and volume
❖ Improved fuel economy and reduced emissions
❖ Extended work piece life by reducing wear and stress surfaces

Grains in same direction will increase the flow rate


Application
3. Dies and mold industry

❖ Reduced production costs


❖ Increased production throughput
❖ Enhanced surface uniformity, finish and cleanliness
❖ Improved die performance and extend life of dies and molds
Application
4. Medical industry (Medical implants)

❖ Eliminate the surface imperfections where dangerous contaminates can


reside
❖ Improved functionality, durability and reliability of medical components
❖ Enhanced uniformity and cleanliness of surfaces,
❖ Extended component life
Thank you

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