Abrasive Flow Machine

By Dr. Harlal Singh Mali

Chapter 1.
Introduction

Abrasive flow machining was developed by Extrude Hone Corporation (USA) in

1960. There are three types of AFM machines that have been reported in the
literature: one way AFM, two way AFM and orbital AFM. Commonly used AFM is
Two-way AFM in which two vertically opposed cylinders extrude medium back and
forth through passages formed by the workpiece and tooling as shown in Fig.1.

Fig.1. Principle of material removal mechanism in two way AFM process

AFM is used to deburr, radius and polish difficult to reach surfaces by extruding an
abrasive laden polymer medium with very special rheological properties. It is widely
used finishing process to finish complicated shapes and profiles. The polymer
abrasive medium that is used in this process possesses easy flowability, better self-
deformability and fine abrading capability. Layer thickness of the material removed is
of the order of about 1 to 10 m. Best surface finish that has been achieved is 50
nmand tolerances are +/- 0.5 m. In this process tooling plays very important role in
finishing of material,however hardly any literature is available on this () of the
process. In AFM, deburring, radiusing and polishing are performed simultaneously in
a single operation in various areas including normally inaccessible areas. It can
produce true round radiieven on complex edges. AFM reduces surface roughness by
75 to 90 percent on cast and machined surfaces. It can process dozens of holes or
multiple passage parts simultaneously with uniform results. Also air-cooling holes on
a turbine disk and hundreds of holes in a combustion liner can be deburred and
radiused in a single operation. AFM maintains flexibility and jobs that require hours
of highly skilled hand polishing can be processed in a few minutes; AFM produces
uniform, repeatable and predictable results on an impressive range of finishing
operations. Important feature that differentiates AFM from other finishing processes
is that it is possible to control and select the intensity and location of abrasion through
fixture design, medium selection and process parameters. It has applications in many
areas such as aerospace, dies and moulds, and automotive industries.

Chapter 2.
Classification of AFM Machine
As mentioned earlier, AFM machines are classified into three categories: one way
AFM, two way AFM and orbital AFM. A brief discussion of the same is given below.

One way AFM process

One way AFM process apparatus is provided with a hydraulically actuated
reciprocating piston and an extrusion medium chamber adapted to receive and extrude
medium unidirectional across the internalsurfaces of a workpiece having internal
passages formed therein, as shown in Fig.2. Fixture directs the flow of the medium
from the extrusion medium chamber into the internal passages of the workpiece,
while a medium collector collects the medium as it extrudes out from the internal
passages. The extrusion medium chamber is provided with an accessport to
periodically receive medium from the collector into extrusion medium chamber.

Fig.2. Unidirectional AFM process

The hydraulically actuated piston intermittently withdraws from its extruding position
to open the extrusion medium chamber access port to collect themedium in the
extrusion medium chamber. When the extrusion medium chamber is charged with the
working medium, the operation is resumed.

Two-way AFM process

Two way AFM machine has two hydraulic cylindersand two medium cylinders. The
medium is extruded, hydraulically or mechanically, from the filled chamber to the
empty chamber via the restricted passageway through or past the workpiece surface to
be abraded(Fig.1). Typically, the medium is extruded back andforth between the
chambers for the desired fixed number of cycles. Counter bores, recessed areas
andblind cavities can be finished by using restrictors or mandrels to direct the medium
flow along the surfaces to be finished.

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 Fig.2A. Two Way l AFM process
Orbital AFM process
In orbital AFM, the workpiece is precisely oscillated intwo or three dimensions within
a slow flowing pad ofcompliant elastic/plastic AFM medium.In Orbital AFM,
surface and edge finishing areachieved by rapid, low-amplitude, oscillations of
theworkpiece relative to a self-forming elastic plasticabrasive polishing tool. The tool
is a pad or layer ofabrasive-laden elastic plastic medium (similar to thatused in two
way abrasive flow finishing), but typicallyhigher in viscosity and more in elastic.

Fig.3. Orbital AFM (a) before start of finishing, (b)while finishing

Orbital AFM concept is to provide translational motion to the workpiece. When

workpiece with complex geometry translates, it compressively displaces and
tangentially slides across the com- pressed elastic plastic self-formed pad (layer of
visco- elastic abrasive medium) which is positioned on the surface of a displacer
which is roughly a mirror image of the workpiece, plus or minus a gap
accommodating the layer of medium and a clearance.

A small orbital oscillation (0.5 to 5 mm) circular eccentric planar oscillation is

applied to the workpiece so that, at any point in its oscillation, a portion of its surface
bumps into the medium pad, elastically com- presses (5 to 20%) and slides across the
medium as the workpiece moves along its orbital oscillation path. As the circular
eccentric oscillation continues, different portions of the work piece slide across the
medium. Ultimately, the full circular oscillation engages each portion of the surface.
To assure uniformity, the highly elastic abrasive medium must be somewhat plastic in
order to be self forming and to be continually presenting fresh medium to the
polishing gap.

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For finishing applications, AFM medium allows the use of a simple arrangement for
feeding and evacuating the abrasive medium pad to achieve uniform results. Regions
of the medium pad that overly fill the gap generally get pushed aside and are shaped
by the oscillation of the workpiece itself. Regions of medium in the gap that are
worked excessively become warmer, due to deformation heating, and consequently
become less elastic and more plastic and are squeezed out of the work gap.

Orbital AFMs small (0.5 to 5 mm) oscillation amplitude allows finishing highly
complex geometries, since all areas except internal features that are even smaller than
the oscillation amplitude are equally worked in the process. The controlled and
cushioned, but still repeated, bumping of the workpiece against the self-shaped tool
imparts beneficial residual compressive stresses to the workpiece surfaces. The
tangential translation of the workpiece across the elastically compressed and
cushioned abrasive particles provides remarkable improvements in surface roughness.

Orbital AFM can be applied to many different workpieces from many different
industries from precision ground aerospace components to cast aluminum wheels.
Coining dies used to make proof coins can be polished from a 0.5 m before surface
to an amazing 0.01 m after finish after only seven minutes of Orbital AFM
processing. Orbital AFM is used to produce extremely fine finishes on the complex
geometry of prosthetic devices while maintaining critical dimensional tolerances.
Beverage container blow molds are finished using the Orbital AFM process
dramatically reducing polishing costs while, at the same time, improving consistency,
increasing production rates, and reducing the need for skilled labor.

Mechanism of Material Removal

The mechanism of material removal in AFM is as follows:

1. Initially, the material is ploughed by the fine abrasives that come in contact with
the work material as they rub over the metal surface with high pressure. The material
flow occurs in the direction of motion of abrasive particles as well as in lateral
direction, resulting into the formation of lips.

2. At the lips, work hardening is noticed due to the rubbing action of the continuous
flowing abrasive particles which are also responsible for intense plastic flow with
considerable stress concentration.

3. The further flow of abrasive particle causes continued work hardening which
results in embrittlement and fragmentation of the lips into microchips.

Material removal mechanism

Polymer based visco elastic medium is extruded back and forth
Flow through a restricted narrow passage in work piece
Medium polymer chains hold abrasive particles flexibly
They orient themselves in the direction of applied extrusion pressure
So medium acts as multi point cutting tool
Medium moves in direction of applied pressure with axial velocity( )
and axial force ( )
is due to viscous component

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 Because of elastic component of medium, it exerts radial force ( )
helps abrasives to indent into the workpiece
pushes the abrasive particle in the axial diection
This removes the material in the form of micro chips

Model for material removal

(5)
Volume of work material removed by indentation
penetration depth
R
Maximum stress developed on the work surface due to normal force exerted by
abrasive grain:

Where area of contact = = h

Hence
The flow stress and Brinell hardness of work piece are related by:
=
Substituting this value of flow stress in previous equation:
h=
Again substituting value of h in Eq. 1 we get
Total volume of material removed in one stroke:
 Vt= Vg Na
Where Na is no. of abrasives in contact with the work piece in one stroke length

Mechanism of material removal follows one of the three conditions:

>

Material is removed in the form of micro- chips

<

No material removal
Only indentation takes place

Material removal removal is just about to start

Force required on the abrasive to remove material in form of micro chip
=
Where = projected area and
= Shear strength of material of work piece

Medium
abrasive

Micro chip
h

Work piece

Rheology
High viscosity medium
Rich in base polymer carrier content and small amount of plasticizers
Has high elastic properties that help in applying large Fr
As such medium yield high material removal per cycle
Low viscosity medium
Rich in plasticizer content
Can easily pass through holes of very small dia. (so useful in micro AFM)

Visco elastic medium

Viscosity + elasticity = viscoelasticity
Viscosity is a fluid property whereas elasticity is a solid property.
So viscoelastic materials have the properties of both solids and fluids.
For elastic materials stress is a function of strain only.
But for viscoelastic materials stress is a function of both strain and strain and
strain rate.
Characteristics of visco elastic materials

(4)

Increasing

Stress strain curve for visco elastic materials may not be unique.
They always show hysteresis loop however small the loading may be.
Strain energy is stored as potential energy and some of it is lost as heat.

Elastic Vs viscoelastic

property Elastic Viscoelastic

Stress strain curve unique Not always unique
Heat dissipation Only when entered into Always dissipated
plastic region
Hysteresis loop Occurs when entered into Always occurs
plastic region
Modelled by springs Spring and dashpot

loading curve

unloading curve

Classification based on rheology

Shear thinning fluids: the viscosity (or apparent viscosity ) goes on decreasing as
shear rate goes on increasing.
The viscosity decreases as the strain rate is increased. At very low shear rates,
the viscosity is nearly a constant, and this constant value is termed the lower
Newtonian region and the viscosity value in this region is called the zero shear
viscosity .

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 As the shear stress or shear rate is increased, there is a decrease in the viscosity,
and the viscosity once again saturates to a constant lower value at higher shear
rates called higher Newtonian region or the second Newtonian region . The
(lower) viscosity in this region is called .

Shear thickening fluids

They are those fluids whose viscosity increases as the shear rate is increased.
These are usually represented by power - law relations with exponent n greater
than 1.
For example: Concentrated suspensions could show shear thickening behaviour
because the particles form sample spanning clusters. This could also result from
occulation of particles due to shear, or due to the jamming of high aspect ratio
particles due to rotation by the shear ow.

Models for visco- elasticity

Kelvin model
First, consider viscous and elastic elements separately. They are usually
represented as shown in below gure . The stress - strain relationships for these
elements are
E = G
V =

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If these two elements are connected in parallel, the total strain for the viscous
and elastic elements is the same, while the total stress is the sum of the stresses
due to the viscous and elastic parts.
= G +
This model is called the Kelvin model for the stress - strain relationship
Maxwell model
The other way to connect the two elements is as shown in gure (b), where the
stress transmitted through the two elements is the same, while the total strain is
the sum of the strains in the two elements. This type of element is called the
Maxwell model .

In this case, the stresses in the two elements are

= GE = V
These two relations can easily be used to obtain the stress - strain relationship
+ M =
where M = (/G) is the Maxwell time constant for this model

Maxwell model

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Chapter 3.
Major Areas of Experimental Research in Abrasive Flow Finishing

3.1 Process parameters and their influence on output responses (Ra and MR)

Experimental investigations have been carried out by various researchers to

investigate the effects of process parameters like extrusion pressure, number of
cycles, viscosity, abrasive concentration and grain size on the output responses
namely, surface finish and material removal during AFM. The controllable input
parameters are shown in Fig.4.

Rhoades experimentally investigated the basic principle of AFM process and

identified its control parameters. He observed that when the medium is suddenly
forced through restrictivepassage then its viscosity temporarily rises. Significant
material removal is observed only when medium is thickened. The amount of
abrasion during AFM depends on design of tooling, extrusion pressure, medium
viscosity and medium flow volume. All these parameters ultimately change the
number of particles interacting with the workpiece and the force acting on individual
abrasive grain. A higher volume of medium flow increases number of interacting
abrasive grains with the workpiece, hence more abrasion takes place. Number of
cycles depend on the velocity of medium, during a given time period. Flow pattern of
medium depends on its slug (medium exiting the workpiece) flow speed, medium
rheology and passage size(cross-sectional area). AFM can be used in industrial
applications such as precision deburring, edge contouring, surface finish, removal of
thermal recast layers, etc.

Williams and Rajurkarused the full factorial experimental design to study the effect of
medium viscosity and extrusion pressure on metal removal and surface roughness.
Mediums viscosity effect is more significant on material removal as compared to
extrusion pressure. It is also reported that major change in the surface finish is
observed after finishing for a few cycle only.

Jain and Adsul reported that initial surface roughness and hardness of the workpiece
affects material removal during AFM process. Material removal and reduction in
surface roughness value are reported higher for the case of softer workpiece material
as compared to harder material. Material removal and reduction in surface roughness
increases when percentage concentration of abrasive in the medium increases. They
also concluded that among all the process parameters studied, the dominating one is
the abrasive concentration followed by abrasive mesh size, and number of cycles.

Loveless reported that the type of machining operation used to prepare the specimen
prior to AFM is important and affects the improvement achieved during finishing. As
compared to the turned and milled surfaces, WEDMd surfaces are found to be more
suitable for AFM. The amounts of material removal from the WEDMd and milled
surfaces are significantly different from that of turning and grinding, because these
machining processes produce different micro surface contours.

Davies and Fletcher reported a relationship between the number of cycles,

temperature and pressure drop across the die for the given type of polymer and

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abrasive concentration. Increase in temperature results in decrease in medium
viscosity and increase in volumetric flow rate. With increase in processing time,
medium temperature increases that causes a change in medium viscosity. They
concluded that rise in temperature is due to a combination of internal shearing of the
medium and finishing action of the abrasive grit.

Fig. 4 Classification of major AFM research areas

3.2 Process modeling and optimization

Williams and Rajurkardeveloped a stochastic model of AFM generated surfaces by

using Data Dependent Systems (DDS) methodology. They have estimated the ratio of
surface roughness peak to valley height (Rz) to centerline average surface roughness
value (Ra) by DDS methodology and found to be between 1.4 and 2.2 for the AFM
process. It was established in their research that AFM finished surface profiles
possess two distinct wavelengths, a large wavelength that corresponds to the main
path of abrasive while the small wavelength is associated with the cutting edges.
Good agreement is found between the primary frequency ranges obtained in DDS
modeling and those derived from spectral analysis function. It is stated that these
frequency bands are related to different material removal modes in AFM;
consequently, the mechanism of material removal in AFM is considered to consist of
ploughing responsible for creation of characteristic flow lines and micro-cutting. They
also proposed an expression for estimating the abrasive grain wear and the number of
active grains (Cd). The estimated value of Cd is used as a cutting life criterion for
abrasives. For small number of cycles its value should remain fairly stable but with
more and more processing the abrasive particles may fracture thereby increasing the
Cd value. The downturn of Cdvalue indicates that the medium has absorbed too much
work piece material and need replacement. Jain et al. also carried out simulation of
finished surface profile and material removed considering the interaction of abrasive
grains with workpiece.

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Rajeshwar et al. proposed a mathematical simulation model to determine the
characteristics of the medium flow during finishing and its experimental verification
was carried out. This model was developed using constitutive equations of Maxwell
model considering the medium characteristics as non- newtonian flow. They reported
that a linear relationship exists between shear stress acting on the surface and the
layer thickness of material removed.

A finite element approach was developed by Jain et. al. for prediction of the stresses
developed during finishing of a cylindrical passage by AFM process (axi-
symmetric flow). In their study it is assumed that medium exhibits linear viscous flow
property and medium properties are independent of temperature and are constant with
regards to time and space. They also presented a theoretical model which is based
upon the consideration that abrasion process in AFM i.e., combination of micro-
ploughingand micro-cutting by assuming that all the abrasive particles are spherical in
shape having a single cutting edge with same size. It is also assumed in this model
that the load acting on each particle is constant and every grain achieves the same
penetration depth depending upon applied load.

Goranaet. al. developed a theoretical model of forces acting on a single abrasive grain
for studying the finishing mechanism of AFM process. Comparison of theoretical
model results with that of experimental data of force and active abrasive grains
densityobtained during AFM process was done.

Fletcher et al. studied the relationship between medium rheological properties and the
AFM process. Shear rate of the polymer increases when it passes through the
restriction (or reduced cross- sectional area). Capillary rheometer is used to find the
relationship between wall shear stress and shear rate for medium viscosity of
polyborosiloxane medium. They concluded that coefficient of viscosity decreases but
shear stress increases as shear rate increases. Variation of wall shear stress with time
is also studied. They also concluded that greater finishing action could be achieved as
a result of longer piston stroke durations, due to higher wall shear stress generated.

Petri et.al.,adopted neural network modeling technique for developing a

comprehensive model for AFM. They presented three neural network models
(Polishing applications, surface removal applications with a circular flow path and
surface removal application with a non circular flow path). Kimbly et al. reported a
set of neural network models that predict the surface finish and dimensional change.
These neural network models are then paired with a heuristic search algorithm to
select sets of machine setup parameters for the AFM process. Lam and Smith
applied Cascade-Correlation neural network modeling to finishing of automotive
engine air intake manifold. They used it to predict the instant at which the finishing
process should terminate to meet the airflow specifications.

Jain and Jain proposed a generalized back- propagation neural network model and a
second network that parallelizes the augmented Lagrange multiplier (ALM)
algorithm. The model determines optimal finishing parameters by minimizing a
performance index subject to appropriate operating constraints. Sarah et al. presented
a neural network model as an off-line controller for AFM of automotive engine

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manifold to predict when the AFM process should be stopped to achieve the required
airflow rate through manifold body.

3.3 Monitoring of AFM process

For online monitoring of material removal and surface roughness in AFM process,
Williams and Rajurkar applied acoustic emission technique (elastic stress waves
generated by the rapid release of strain energy within a material due to a
rearrangement of its internal structure is called "acoustic emission"). In a full factorial
experiment, the effect of extrusion pressure, medium viscosity, abrasive grit size,
number of cycles, and work piece material was investigated on material removal, root
mean square of acoustic emission signal (AERMS), and surface roughness
improvement. From the above parameters only grit size showed insignificant affect on
material removal. They studied acoustic emission signals for grinding to analyze the
mechanism involved in AFM and found that the acoustic emission signal is highly
dependent on the characteristics of the initial surface roughness of the workpiece. The
AERMS of the signal is sensitive to extrusion pressure and other AFM process
parameters, which affect material removal.

They used Data Dependent Systems technique to analyze the acoustic emission signal
acquired during AFM processing. In DDS analysis, they found that main root of
frequency of signal was around 160 kHz and secondary root with less power had a
frequency around 80-90 kHz. They reported the fact that the higher frequency
component is associated with the ploughing mechanism that would agree with the
results obtained during grinding. They also found that aluminum workpiece give
stronger signals than steel workpiece because of higher material removal from
aluminum workpiece as compared to steel under identical finishing conditions. This
suggests a strong correlation between material removal rate and acoustic signal in
AFM.

3.4 Recent developments in AFM processes

Though there are many advantages of AFM process, it has a few disadvantages also,
such as low finishing rate, and incapability to correct the form geometry. Many
researchers have been working to improve the finishing rate, surface integrity and
compressive residual stresses produced on the workpiece surface.
Singh and Shan applied magnetic field around the workpiece in AFM and observed
that magnetic field significantly affect the material removal and change in surface
roughness. With the application of magnetic field, less number of cycles are required
for the higher material removal. Higher material removal and higher change in surface
roughness are observed (in case of brass as workpiece material) with the low flow
rates of medium and high magnetic flux density.

Chapter 4.
Applications of AFM
4.1 Automotives

The demand for this process is increasing amongst car and two wheeler
manufacturers, as it is capable to make the surfaces smoother for improved air flow
and better performance. AFM process is used to enhance the performance of high-

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speed automotive engines. AFM process is capable to finish automotive and medical
parts, and turbine engine components [Fig.7]. Internal passages within a turbine
engine diffuser arepolished to increase air flow to the combustion chamber of the
engine. The rough, power robbing cast surfaces are improved from 80-90% regardless
of surface complexities.

Fig 5. Grains in the same direction to increase flow rates.

4.2 Dies and Moulds

Since in the AFM process, abrading medium conforms to the passage geometry,
complex shapes can be finished with ease. Dies are ideal workpieces for the AFM
process as they provide the restriction for medium flow, typically eliminating
fixturing requirements. The uniformity of stock removal by AFM permits accurate
'sizing' of undersized precision die passages.

The original 2m Ra (EDM finish) is improved to 0.2m with a stock removal of

(EDM recast layer) 0.025mm per surface (Fig. 6).

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 Fig 6. Use of AFM in Dies and Moulds industry
Chapter 5.
Concluding remarks

AFM is a well-established advanced finishing process capable of meeting the

diverse finishing requirements from various sectors of applications like aerospace,
medical and automobile. It is commonly applied to finish complex shapes for better
surface roughness values and tight tolerances. But the major disadvantage of this
process is low finishing rate. So continuous efforts are being made to increase
finishing rate, improve surface texture and to some extend to improve MRR. To
achieve an accurate and efficient finishing operation without compromising the
finishing performance, understanding of inter relationship between various input
parameters and output responses that influence the process performance. This leads to
identification of various optimal finishing conditions from the infinite number of
combinations and their modelling. The better performance is achieved if the process is
monitored online. So, acoustic emission technique is tried to monitor the surface
finish and material removal but ended with only marginal improvement. Later various
modelling techniques (mathematical, analytical and empirical) are used to model this
process to correlate with experimental results. To overcome the disadvantages of the
process, many modifications (M- AFM, CFAAFM, DBGAFF, R-AFF and spiral
polishing method) have been tried. But in spiral polishing, CFAAFM and DBGAFF
processes, the probability of role of additional tooling which is at the middle of the
slug has less influence on the finishing direction of active abrasive grain. Butrotating
the workpiece itself solves this problem. It makes the active abrasive grains to follow
helical path, which improves the contact length of the active abrasive grain with
workpiece. In R-AFF process, better improvement in surface roughness is achieved
compared to AFM and takes lesser time to achieve same surface finish that can be
achieved through AFM process. But authors feel that there is still room for lot of
improvements in the present AFM status.

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