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Journal of Manufacturing Technology Research ISSN: 1943-8095
Volume 5, Number 3/4 2014 Nova Science Publishers, Inc.

STATE OF ART ON MICRO-ABRASIVE FLOW

FINISHING (-AFF) PROCESS

Sachin Singh , M. Ravi Sankar, and U. S. Dixit

Department of Mechanical Engineering,
Indian Institute of Technology Guwahati, India

ABSTRACT
Advancement in technology demands for more miniature and complicated systems.
Finishing of miniature as well as micro components with complex geometries and are
made of difficult to finish materials pose the challenges to the manufacturing industries.
To meet these new challenges many advanced finishing processes such as abrasive flow
finishing (AFF), magnetic abrasive finishing (MAF), magnetorheological finishing
(MRF), and magnetorheological abrasive flow finishing (MRAFF) have been developed.
One of the most important abrasive micro finishing is micro abrasive flow finishing (-
AFF). A survey in the field of -AFF is presented in the present paper.

Keywords: Nano-finishing; Micro-Abrasive flow finishing, Deburring

1. INTRODUCTION
The final operation performed in most of the manufacturing process is finishing. Surface
roughness plays a vital role on important functional properties such as wear resistance and
power loss due to friction on most of the engineering components. Hence performance of the
component also depends on the surface roughness. If the surface is not smooth and contains
irregularities it can lead to failure of a component because of crack-generation from surface.
Recent engineering technology development leads to complex 3-D components with
miniature features made of advanced materials. These components need nano-level surface
finish, which is not easily attainable with the traditional fine finishing processes. An
improvement in the product quality requires advancement in finishing process to achieve
desired goal. Industries have to take care that the process should be economical, less complex
and fast. Finishing operations can cost as much as 15% of the total manufacturing cost in a
production cycle [1-2]. Even for improving surface finish by one micron, the cost increases
greatly. The applications of almost all the traditional abrasive finishing processes such as

E-mail: evmrs@iitg.ernet.in
168 Sachin Singh, M. Ravi Sankar, and U. S. Dixit

grinding, honing, lapping are limited to the production of simple and easily accessible
geometries such as flat and cylindrical shapes. These abrasive processes often induce thermal
damages into the workpiece [3]. To meet all these challenges a new nontraditional finishing
process known as abrasive flow machining (AFM) was developed by Extrude Hone
Corporation, USA in 1960s. In recent times abrasive flow machining process is mainly used
for nano-finishing, thus this process is also called as abrasive flow finishing (AFF) process.
It can finish from simple to inaccessible pathways of the various geometries easily by
allowing abrasive laden polymeric medium to flow over it. AFF Medium mainly comprises of
the base polymer which is viscoelastic in nature, additives (plasticizers, softeners) and
abrasive particles. As shown in Figure 1 , when the abrasive particle comes in contact with
the surface roughness peaks, it act as a miniature cutting tool removing surface roughness
peaks and providing a smooth surface after finishing operation. Further to finish miniature
and micro components (1 m dimension 999 m) -AFF is developed.

Figure 1. Workpiece surface (a) before AFF finishing operation (b) after AFF finishing
operation.

1.1. Abrasive Flow finishing (AFF)

AFF is one of the advanced finishing processes, which is used to achieve high surface
quality on internal and external difficult to finish pathways [4-8]. The first patent [9] on the
process was granted to Extrude Hone Corporation a US based company. AFF process can
achieve surface finish up to 0.05 m, holes as small as 0.2 mm can be deburred, radius edges
from 0.025 to 1.5 mm and hole tolerance up to 5 m can be held [2]. There are four types of
AFF machines that have been reported in the literature: one way AFF, two way AFF, orbital
AFF and -AFF. The commonly used AFF is two-way AFF. As shown in Figure 2 its setup
consists of upper and lower media cylinders with pistons, workpiece xture, hydraulic drive
and supporting frame. The workpiece to be finished is held in the fixture securely and placed
in the space between the upper and lower media cylinders. Under the action of an external
force hydraulically or mechanically, the media is extruded via the restricted passage through
or past the workpiece surface to be machined.
When the upper media cylinder had discharged media to lower media cylinder, the lower
media cylinders piston begins to push the abrasive back to upper cylinder completing one
cycle, thus circulating the media back and forth through the workpiece till the desired results
are obtained. Advantage of two way AFF lies in the fact of finishing even complex
geometries by proper designing of tooling so that media can be guided to the selected portion
that need to be finished.
 State of Art on Micro-Abrasive Flow Finishing (-AFF) Process 169

Figure 2. Two-way AFF process (a) Downward moment of upper piston (b) Upward
movement of lower piston).

1.2. Micro-Abrasive Flow Finishing (-AFF)

For finishing micro components easily micro-abrasive flow finishing (-AFF) process is
developed. Some of commonly finished micro components include micro bores of diameter
less than 500 m found in various products such as biomedical filters, high-pressure orifices,
ink-jet printer nozzles, and fuel injection nozzles. -AFF is nearly the same process as two
way AFF. The main difference is that in -AFF lower viscosity media and smaller sized
abrasive particle are used as compared to AFF. This helps in an easy flow of the media even
through very small passages of workpiece. The lighter micro flow media has sufficient
viscosity at lower shear rates to remain homogenous and maintains a uniform distribution of
the abrasive particles. When the media enters the narrow pathways, it accelerates resulting in
deburring, radiusing and surface finish improvement with a consistent flow rate. All
important features of the process, from medium viscosity and medium pressure to shear force
history and temperature in -AFF are accurately monitored by sophisticated precision sensing
devices in a closed loop system [10-11].

2. DEVELOPMENT IN -AFF PROCESS

2.1. Micro Abrasive Flow Finishing (-AFF) Set up

To test the suitability of AFF process for polishing micro-bores ranging from sizes 260-
500 m commonly found in various products such as biomedical filters, ink-jet printer
nozzles, fuel injection nozzles, high pressure orifices, Yin et al. [12] designed abrasive flow
polishing machine and conducted various experiment. Researchers conducted polishing of 4
specimens, S45C bores of 400 m and 500 m diameters, stainless steel 304 bores of 500 m
diameter as well as zirconia bores of 260 m diameter. A stylus profilometer was used to
170 Sachin Singh, M. Ravi Sankar, and U. S. Dixit

assess the surface roughness of the inner walls of micro bores which were further viewed
using an optical interference profilometer. With an increase in abrasive flow, the surface
roughness of micro bore inner wall decreases.
Rhoades et al. [13] provided a method of controlling flow resistance in the orifices to
attain a precise predetermined flow resistance. The main objective of this invention was to
attain a particular dynamic property during the use of orifice, not specific dimension.
Tzeng et al. [14-15] performed AFF process on the micro parts fabricated by using EDM
process. Finishing experiments were performed on the micro hole ( 0.3 mm) and micro slit
(width of 0.23.02 mm) which are made by electric discharge machining (EDM) on stainless
steel. During EDM micro hole drilling, some melted and un-expelled material forms a recast
layer on the machined surface which strongly affects the quality of the micro parts.
Researchers explored the effects of AFF parameters, such as motion mode (rotary or non-
rotary), extruding pressure, extruding time, abrasive concentration, abrasive particle size, and
finishing time on MRR as well as surface roughness of micro hole. Same experiments are
performed with micro slit except the parameters motion mode and extruding time. The
optimum levels of AFF process parameter combinations were found. Researchers found out
that AFF process is more suitable for finishing of micro geometries that are developed by
wire EDM process because AFF process easily removes the recast layer that forms on micro
geometry during wire EDM process. With an increase in extruding pressure and finishing
time the magnitude of finishing force as well as duration of acting on workpiece surfaces
increases. It results in improvement of MRR and surface finish. In case of finishing of micro
slit, temperature was experimentally measured and it was observed that temperature change is
below 5C when abrasive size particle, concentration, extrusion pressure and finishing time
are varied.
Experimental investigation to study the effects of AFF on performance of direct injection
diesel engine fuel injector nozzle (diameter~165 m) was done by Jung et al. [16-17]. In
another study, the researcher used numerical engine cycle simulation model to study the
impact of the geometric changes of the nozzle after processing with AFF process on the
engine performance and emissions. EDM process is mainly used to drill micro holes in fuel
injector nozzles. Typical EDM for the injector nozzle leaves burrs and a rough surface inside
the hole. It is observed that AFF processing of micro-hole is not a uniform process i.e. the
finishing area shifts with time. At the beginning of AFF process material is mainly removed
from the inlet corner and a chamfered inlet appears. On the other hand, diameter increases
gradually after the inlet chamfer and surface is finished. Smoothly chamfered nozzle inlet
reduces flow restriction and improves discharge coefficient of the nozzle. Thus the fuel flow
rate increases which promotes fuel spray atomization and air-fuel mixing. The AFF processes
may cause undesired enlargement of the nozzle hole which adversely affects the emissions.
Hence size of the EDM hole should be properly determined taking into account the
enlargement effect of the AFF process, so that the final nozzle hole diameter should be of
desired size.
Several researchers [18-24] designed the experimental set-up to finish complex internal
passages of components and micro holes found in common rail pipe, injector nozzle of oil
supply system of the diesel engine. Due to the complex shape of the parts, it is difficult to
finish by any other finishing operation compared to AFF process. The various part of the
experimental set up such as abrasive cylinder, bearing of the hydraulic and abrasive cylinder,
base plate were modelled for force analysis in order to check the design of the parts to meet
 State of Art on Micro-Abrasive Flow Finishing (-AFF) Process 171

the requirement of strength and rigidity. Wu et al. [23] developed AFF set-up for finishing
pipes having small internal diameter and found out that surface roughness of pipe inner wall
greatly improved after finishing it with AFF process.

2.2. Micro Abrasive Flow Finishing (-AFF): Tooling

The main purpose of -AFF is to hold the miniature components and to guide the
abrasive media properly without leakage through them. The tooling for two way AFF and -
AFF are different. In -AFF the dimensions of the component are in microns, one of the way
for properly guiding the media through the narrow passage of the workpieces is to use tapered
tooling/fixturing that starts from the medium exit at the medium cylinder to the component
entrance will be more steeper (Figure 3).

Figure 3. Schematic diagram of -AFF tooling.

AFF is well suited finishing method for hole diameter greater than 20 mils (1 mil.025
mm), but in case of holes less than 20 miles and width as small as 1 to 5 mils, it is not easy to
force the medium through small openings. To overcome such shortcoming of AFF, Perry [25]
invented a new method and improved tooling for radiusing as well as finishing small holes in
workpieces such as steel, aluminum and titanium .The tool acts as a means for directing at
least a first portion of media about a workpiece i.e. from one side of workpiece to opposite
side. At the same time the second portion of media is pushed to easily flow through the holes.
After exiting from the hole the first and second portion of media intersects in such a manner
that a swirl effect sets up in the media which permits the flow of media through the holes.
Li et al. [18] designed the tooling for finishing of common rail parts. They used a hose
pipe whose one end is connected to the abrasive cylinder while the other end is connected to
172 Sachin Singh, M. Ravi Sankar, and U. S. Dixit

one of the five branches of the common rail parts. The remaining branches are kept blocked
by the end cover thus improving finishing precision and efficiency. Guo et al. [26] performed
3-D numerical simulation of AFF operation while finishing of micro holes in common rail
pipe. Researchers established the relationship between processing quality of AFF process and
inlet/outlet pressure differences, volume fraction of abrasives etc. Li et al. [19, 27] designed
the tooling for proper holding and finishing of micro nozzle and also developed a method for
controlling the speed of abrasive cylinder piston which helps in improvising -AFF efficiency
and accuracy. The tooling consists of two clamps, the upper clamp is connected to the U-
shaped tube while the lower clamp is fixed to the abrasive cylinder and the nozzle is fixed in
between the two clamps. The rear of the nozzle is embedded in the center bore of lower clamp
with equal diameter while the upper part is embedded in the upper clamp.

2.3. Micro Abrasive Flow Finishing (-AFF): Media

From the literature survey there are three main things that distinguish -AFF process
from AFF are tooling, media viscosity, and abrasive particle size used for finishing the
component. Commercial media viscosity levels are specified using number systems. For -
AFF number system less stifflow viscosity and for AFF high stiffhigh viscosity or medium
viscosity media is used. AFF mainly employ various abrasive particles whose sizes ranging
from coarse mesh size 8 with an average particle size of 4620 micron to mesh size 800 with
an average size of 12.0 microns. Very fine around 1200 grit with an average size of 6.5
microns, is used for -AFF process.
Medium is most important component in AFF or -AFF process. Compared to AFF
process, in -AFF process the viscosity of medium is low and abrasive particles used will be
very fine. Medium viscosity can be reduced by addition of more and more plasticizer [28].
Plasticizers (processing oils or dispersants) are small molecules and do not have long chains.
Their molecules are chemically similar to the base polymer. As shown in Figure 4
Plasticizers small molecules diffuse between long polymer chains thus increasing gap
between the long polymer chains which results in increasing mobility and reduced viscosity.

Figure 4. Diffusion phenomenon of low molecular weight plasticizer in between polymer

chains (a) Polymer chains with no plasticizer molecules, (b) low volume of plasticizer
molecules getting diffused between polymer chains, and (c) high volume of plasticizer
molecules getting diffused between polymer chains [28].

Viscosity of the media can also be reduced by using a temperature sensitive media whose
viscosity decreases with increasing temperature (Figure 5).
 State of Art on Micro-Abrasive Flow Finishing (-AFF) Process 173

Figure 5. Effect of temperature on shear viscosity for different volume percentage of

plasticizer in the medium [28].

The rheological study of the commonly used polyborosiloxane as base polymer during
AFF finishing operation was done by Hull et al. [29]. From the study researchers concluded
that media shows time dependent rheological behaviour i.e. it stores a history of shear and
behaves accordingly. Rhoades [30] developed the media useful for abrading or deburring
metal parts by extruding it through the inaccessible openings. The primary components of the
media are guar gum, boric acid, and borax. The main invention was that medium can easily
be modified to suit the size of the opening. It is preferable to use a less viscous media in small
holes having dimensions in microns. The abrasive particle used with the media can be boron
carbide, silicon carbide, aluminum oxide, tin oxide, diamond rust, corrundum, garnet, and
glass. The choice of abrasive particle depends upon the nature of workpiece material to be
finished. The particle diameter used in the invention preferably runs from about six to ten
microns up to about 16 mesh size. Perry [31] developed abrasive liquid slurry for polishing
and radiusing a microhole. This invention is based upon a meaningful correlation between the
flow rate of the liquid slurry through a micro hole to a target flow rate, and when the flow rate
of the abrasive slurry reaches a predetermined flow rate, the microhole is properly calibrated
for the target liquid. The slurry used in the invention comprises liquid material (napthenic
mineral oil), a theological additive (polyethylene) for creating thixotropic slurry and abrasive
particles (silicon carbide, boron carbide, diamond) with mesh size from 400 to 1000.
Tzeng et al. [32] developed a self-modulating medium to finish micro-channel surfaces.
The viscosity and fluidity of the medium can be adjusted online while the process is going on.
The main constituents of the medium are polymer, wax, silicone oil and silicon carbide (SiC)
abrasive particles. Further, the effects of self-modulating abrasive media on viscosity, surface
roughness and micro channel shape precision are studied.
Kar et al. [33-34] made an attempt to replace costly carriers like silicon or
polyborosiloxane rubber (PBS). The finishing of two types of material aluminum and En8 is
174 Sachin Singh, M. Ravi Sankar, and U. S. Dixit

carried out. Researchers experimented with five types of carriers viz. natural rubber (NR),
ethylene propylene diene monomer, rubber, butyl rubber, silicone rubber and styrene
butadiene rubber. They concluded that styrene butadiene rubber as a viscoelastic carrier for
media gave the best improvement in surface nish out of all the carriers used. Gao et al. [35]
also used SBR as AFF finishing medium for finishing of complex and miniature parts used in
aerospace industry made up of titanium or aluminum alloy and reported that SBR has good
finishing efficiency.
Lunn [36] emphasised the need of incorporating at least one thermoplastic polymer in the
traditionally used abrasive media. The objective of adding thermoplastic polymer (styrene
polymers) is to enhance the elastomer properties (elasticity, compression resistance,
relaxation time) which help in achieving uniform finishing action in passageways having
large L/D ratio.

2.4. Micro Abrasive Flow Finishing (-AFF) Applications

Process such as micro debburing, edge radiusing, and surface finish of micro holes
ranging from size 50 m to 750 m can be done in one go by -AFF process. The -AFF
finds its application in finishing of products such as biomedical filters, high-pressure orifices,
ink-jet printer nozzles, common rail pipes and fuel injection nozzles. It is also used in
finishing of micro holes ranging from sub millimeter to micro holes of turbine blades. It is
ideally suited in diesel and automotive industry in the manufacture of fuel systems especially
fuel injector nozzles. The -AFF process finishes microholes in fuel injector nozzles and
improves geometry by smoothing the rough EDM surface. Small geometric improvement in
nozzle can enhance the engine performance which is successfully achieved by processing the
nozzle with the -AFF process. The -AFF produces a much lower surface roughness as
compared to EDM. This process also helps in radiusing the entrance of injection nozzle. The
-AFF finished fuel injector nozzle maintains a consistent flow rate within specified limits.
The finished nozzles have a smoother surface finish and definite exit radius which leads to
better atomization of fuel which increases engine performance, power and reduction of
emissions as well as crack propagation.

CONCLUSION
Micro AFF process due to its good finishing capability is gaining importance in modern
manufacturing industries. Several set-ups and tooling were invented by the researchers for
finishing miniature components as well as components having miniature features. Abrasive
liquid slurry especially for polishing and radiusing micro holes was also invented by
researchers. The -AFF process proved its feasibility in finishing micro holes of 260-500 m
diameters and 25-50 m L/D ratios for both metals and ceramics and producing at least 60%
reduction in surface roughness. EDM produced direct injection diesel engine fuel injector
nozzles having surface roughness of 1.24 m (164.81 m mean diameter). After finishing
with -AFF process a smoother surface with 0.18 m surface roughness was achieved this
improved engine performance. Micro orifices were also finished with the help of -AFF
process its surface roughness improved from 2.4 m to 0.8 m. Attempts to know the
 State of Art on Micro-Abrasive Flow Finishing (-AFF) Process 175

significant finishing parameters and the optimal combination levels of finishing parameters
during finishing by -AFF process were also made. For fabricating -AFF stepup, some
researchers checked the reliability of their designed setups in terms of strength and rigidity by
the finite element simulations. Till now, no attempts have been made to determine the
finishing forces acting during -AFF process.

ACKNOWLEDGMENTS
The authors acknowledge the financial support provided by Indian Institute of
Technology Guwahati (Project Number: SG/ME/P/MRS/1). Authors are also thankful for
Department of Science and Technology FIST project number: SR/FST/ETI-244/2008.

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