Study on key parameters of a new abrasive flow machining (AFM) process for surface finishing

The conventional abrasive flow machining (AFM) and its derivatives (i.e., magneto, electro-chemical, and ultrasonic-aided AFMs) demand special machining devices, which limits the application and dissemination of AFM. A new AFM is developed in this study, which demands no extra special devices except for a tool bar made with cemented carbide. The effect of dynamic viscosity of abrasive medium, standoff distance, and tool bar rotating speed on pressure and velocity distributions of flow field is investigated using a numerical model. Moreover, experiments are conducted to explore the influence of abrasive-laden medium and process key parameters on this new AFM finishing effect. The results indicate that the pressure and velocity of flow field reach their maximum at the middle of the minimum standoff distance between tool bar and workpiece. The optimum abrasive grain size utilized in this AFM is found to be related to the minimum standoff distance between tool bar and workpiece during finishing process. The obtained optimum tool bar rotating speed, traverse speed, and number of processing cycles are 19,200 r/min, 500 mm/min, and 500 cycles, respectively. This new AFM is anticipated to become an efficient and economic tool for surface finishing.