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1. INTRODUCTION
AFM process has a greater potential of being used to deburr, radius, polish and remove recast
layer of component. With the use of AFM, excellent surface finishes and close geometric
tolerances can be attained economically. The media in the AFM process is used to polish
difficult-to-reach areas, and to follow complex geometries and microholes. The media consists of
a type of polymeric carrier and abrasive particles that are SiC, Al2O3, diamond, etc. (Rhoades,
1987; Loveless et al, 1994). But limited efforts have been done towards enhancing the
productivity of AFM process with look upon to superior quality of work piece surface (Jain and
Jain,1999). In order to meet the challenges of high surface quality and tolerance requirements,
often coupled with high production rates of parts having complex shapes and contours (Dubey et
al, 2008) and for the finishing of hard materials (Kim and Choi, 1997; Yan et al, 2003), the
concept of hybrid machining (HMP) is currently gaining attention
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DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016
USM
AFM
UFP
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DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016
(MAAFM) (Singh et al, 2001; Singh and Shan, 2002). They concluded that the effect of
magnetic field is observed only on non-ferromagnetic work materials. The investigations showed
that under the effect of magnetic field, brass work-piece experiences more abrasion as compared
to aluminium work-piece. Further it was observed that the magnetic field does not appreciably
improve surface roughness of aluminium work-pieces while significant improvement was
observed in case of brass specimens.
2.4 Magnetorheological Abrasive Flow Finishing (MRAFF)
Jha and Jain (2004) developed a new precision finishing process, Magnetorheological Abrasive
Flow Finishing (MRAFF), by combination of abrasive flow machining (AFM) and
magnetorheological finishing (MRF), for complex internal geometries.
MRAFF process provides better control over rheological properties of abrasive laden.
Magnetorheological (MR) polishing fluid comprises of carbonyl iron powder and silicon carbide
abrasives dispersed in the viscoplastic base of grease and mineral oil; it exhibits change in
rheological behaviour in presence of external magnetic field. This smart behaviour of MR-
polishing fluid is utilized to precisely control the finishing forces, hence final surface finish. The
role of magnetic field strength in MRAFF process is clearly distinguished, as at zero magnetic
field conditions no improvement in surface finish is observed, and the improvement is significant
at high magnetic field strength (Das et al, 2008).
Figure 3. Magnetic Assisted Abrasive Flow Machining (MAAFM)(Singh, 2002)
1. Upper Media Cylinder and Flange, 2. DC Electromagnet 3. Lower Media Cylinder and Flange,
4. Workpiece, 5. Upper Fixture Plate, 6. Lower Fixture Plate, 7. Magnetic Abbrasive Particles
Figure 4. Magnetorheological Abrasive Flow Finishing (MRAFF) (Jha and Jain, 2004)
MRAFF is a process whose fluid flow properties can be controlled by altering the magnetic field
for the hard or soft materials as per the requirement.
2.5 Centrifugal Force Assisted AFM (CFAAFM)
Walia et al (2006) developed this new Hybrid AFM process. The application of centrifugal force
(by using rotating rectangular rod inside the hollow workiece) had been explored for the
productivity enhancement of the process. Walia et al (2006)a optimized this process by using
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DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016
Taguchi Method, developed FEM model (Walia et al, 2006b), used Utility concept to multi-
response optimization of CFAAFM (Walia et al, 2006c), developed analytical model (Walia et
al, 2009), improved the fixturing for the provision of rotating rod inside the hollow cylindrical
work-piece (Walia et al, 2009b). It has been reported that centrifugal force enhances the material
removal (MR) and improves the surface finish and scatter of surface roughness (SSR) value in
AFM leading to the development of Centrifugal Force assisted AFM (CFAAM) (Walia et al,
2008).
The application of centrifugal force (by using rotating rectangular rod inside the hollow work
piece) had been explored for the productivity enhancement of the process by Walia et al, 2009a)
Centrifugal Force assisted Abrasive Flow Machining (CFAAFM) which involves increasing the
pressure on the abrasive particles in the media while they contact the surface of work piece
during processing. This has been achieved by providing a centrifugal force generating (CFG) rod
with rotational mechanism in the AFM setup that helps the media to simultaneously rotate at a
speed while being axially pushed. The rotation of rod causes a centrifugal force to act on the
media, which in turn increases media contact quality. The modified process has been termed as
Centrifugal Force assisted Abrasive Flow Machining (CFAAFM). This new process also helps to
increase the reduction ration ratio for a given work piece geometry compared to conventional
AFM process. It has been reported that centrifugal force enhances the material removal (MR)
and improves the scatter of surface roughness of work piece processed by AFM process.
Figure 5. Centrifugal Force assisted Abrasive Flow Machining (CFAAFM) (Walia, 2006)
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DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016
of surface finish, while the combination of a larger grain size and a higher speed of the CFG rod
causes higher material removal.
Brar et al (2012) experimented with the electro-chemical aided abrasive flow machining
(ECA2FM) using NaI salt-abrasive laden medium with an axially held cylindrical electric rod as
the cathode, whereas the conductive material work-piece as anode. They found that the abrasion
of the material is intensified due to the cooperation of electro-chemical dissolution and the
material removal goes on increasing with the increase in applied voltage.
2.7 Electrically Controlled Polishing
Akagami and Umehara (2006) developed an electrically controlled polishing process. A
dispersion type functional fluid and AC electric field was used to control the distribution of
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DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016
abrasives in free-abrasive polishing and to improve surface roughness and finishing time. A
conductive cement carbide plate was polished under AC electric field gradient of 2 kV/mm and
0.8 Hz frequency, using a mono-pole electrode. It reduced the surface finish of part from 0.65
micron Ra to 0.02 micron Ra in 5 min. For a non-conductive borosilicate glass plate, a multi-
layered concentric electrode was used and the surface roughness decreased from 13.5 nm Ra to
7.5 nm Ra in 3.5 min.
2.8 Drill Bit-Guided Abrasive Flow Finishing (DBG-AFF) Process
To improve surface texture by abrasive flow finishing (AFF) process, drill bit guided (DBG)
AFF process has been proposed (Sankar et al, 2009). The major difference between AFF and
DBG-AFF machines is in its tooling. In DBG-AFF process a drill bit is placed in the media flow
path, for the simultaneous rotation of abrasives laden media and observed better results due to a
combination of abrasives laden media flows leading to better mixings of media and thus more
number of active grains. The inner part of medium slug flows along the helical flute which
creates random motion among the abrasives in inner region of the medium. This causes
reshuffling of abrasive particles at outer region. Hence, comparatively more number of new and
fresh abrasive grains interacts with the work-piece surface. It results in higher finishing rate in
DBG-AFF as compared to AFM. The abrasive intermixing depends not only on the medium self-
deformability but also on the pressure from the drill bit being exerted on the medium
(reciprocating axial flow, flow along the flute, and scooping flowall the three flows take place
at the same time). It has also found that material removal decrease with decrease in drill bit
diameter.
Due to the combination of different modes of flow, the work-piece (AISI 4340)abrasive contact
length is no longer a straight line, rather it becomes inclined. Hence, the number of peaks that
can be sheared off in a single cycle increases, leading to higher material removal rate hence
finishing rate also (Jain, 2009).
Figure 7. Drill Bit Guided (DBG) AFF (Sankar et al, 2009)
Incorporation of rotating rod and further improvement of rotating drill bit lead to the
development of centrifugal forces in the media. Thus more material is removed from the work-
piece surface and surface finish is also better.
2.9 Rotational Abrasive Flow Finishing (R-AFF)
Sankar et al, (2009)a made an effort towards improving the performance of AFF process by
externally rotated tooling and the reciprocation of medium with the help of hydraulic actuators
(R-AFF). The experiments were conducted on Al alloy and Al alloy/SiC metal matrix
composites (MMCs). They found that as the number of cycles increases, Ra increases. Ra also
increases as extrusion pressure and processing oil content increase till 6.5MPa and 10%,
respectively, and then start decreasing gradually. Among three workpiece materials, better Ra is
achieved on Al alloy/SiC (10%) MMC. The experimental study reported that R-AFF can produce
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DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016
44% better Ra and 81.8% more MR compared to AFF process. They proposed the mechanism
of material removal of matrix and reinforcement in MMC (Sankar et al, 2010).
The scientific logic behind finishing mechanism of matrix and reinforcement, cross hatch
patterns, helical path directions, micro-scratch (-scratch) width and depth variation with size,
orientation and support that active abrasive grain obtains from neighboring abrasives was derived
from scanning electron microscopy micrographs. The developed mathematical model to
calculate helix angle and helical path length in finishing region shows a good concurrence with
the experimental helix angle and helical path length (within 82.5% accuracy). They also
observer, as the work-piece rotational speed increases, the experimental helix angle gradually
decreases and helical finishing path length steadily increases. As a result, %Ra increases with a
decrease in helix angle (Rajesha et al, 2010).
Figure 8. Rotational Abrasive Flow Finishing (R-AFF) (Sankar et al, 2009)
R-AFF generates micro cross hatch pattern on the finished surface that can improve lubricant
holding capabilities.
2.10 Helical AFM (HLX-AFM) Process
Sharma (2011) developed a helical-AFM setup with the use of a stationary-coaxially held drill-
bit of two start. The drill bit is held axially inside the cylindrical surface to be machined. As the
media extrudes through the recess it follows the helical path and a combination of axial, radial,
centrifugal forces leads to improved surface finish and more material removal. He observed that
material removal increased by a factor of 2.66 over the basic AFM process, along with a
maximum percentage improvement in surface roughness of 74.69%. The increase in efficiency is
due to increase in active grain density due to a combination of flows as well as due to increased
cutting forces on the active abrasive grains. Singh P. further improved the performance of HLX-
AFM by using different helical profiles namely, drill bit of three starts and a spline (Singh,
2011). More improvement in surface roughness of 61.4% was observed for three-strat helical
profile with no effect on material removal (means no extra machining effort).
Figure 9. Helical Abrasive Flow Machining Process (HLX-AFM) (Sharma, 2011)
Kumar (2012) employed HLX-AFM process for the processing of different work-piece materials
namely mild steel, brass and aluminium. More material removal was observed in brass than the
mild steel work-pieces and so is the percentage improvement in surface roughness. Although,
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DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016
aluminium is soft and more volumetric material removal takes place (highest percentage
improvement in surface roughness was reported), but low material removal (in mg) was reported
due to the low density of aluminium. Again the three-start profile is the most effective among the
selected profiles in improving the surface roughness. Wang et al. developed a mechanism with a
four helices passageway to perform multiple flowing paths of abrasive media, whose flowing
behaviour enhanced polishing effectiveness and uniformity of the surface finish by increasing the
abrasive surface area and radial shear forces (Wang et al, 2012).
Brar et al (2012)a uses the Helical Abrasive Flow Machining Process (HLX-AFM) for the
finishing of internal cylindrical surfaces. An improvement in the material removal and surface
finish has been observed with the use of a coaxially fixed helical twist drill bit during the
abrasive flow machining process. This simple process modification significantly enhances the
process performance in comparison to the basic AFM process.
2.11 Rotational-Magnetorheological Abrasive Flow Finishing (R-MRAFF) Process
Das et al (2012) proposed a new finishing process Rotational-Magnetorheological Abrasive Flow
Finishing (R-MRAFF) to enhance the performance of MRAFF process (Jah et al, 2007). In this
process, a rotation cum reciprocating motion is provided to the polishing medium by a rotating
magnetic field and hydraulic unit. By intelligently controlling these two motions, a uniform
smooth mirror-like finished surface with improved material removal rate and finishing rate
(nanometer per cycle) is achieved for both stainless steel and brass work-pieces. They found that
R-MRAFF process produces better results than MRAFF. They also observed that the abrasive
cutting marks generate cross-hatch pattern on the surface finished by R-MRAFF process.
They found that the combinations of rotational speed of the magnet and its square term together
have the highest contribution to the percentage improvement in surface roughness. Other
significant parameters in the order of decreasing percent contribution to the change in surface
roughness value are finishing cycles, extrusion pressure, and fluid composition. They also found
that the best surface finish obtained on stainless steel and brass work-pieces with R-MRAFF
process as 110 and 50 nm, respectively.
Figure 10. R-MRAFF process (Das et al, 2012)
8
DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016
media cannot be scooped up and down as a lump. Yan et al (2007) applied the spiral polishing
method via a micro lapping generated surface by transmission of an abrasive medium through a
screw rod and they obtain a fine polished surface by removing tiny fragments. They also found
that this method is not dependent on the size of the work-piece's application area in order to carry
out the process. Chen et al (2010) studied the spiral polishing mechanism in polishing the inner
wall of stainless bore with the mixture grinding material of silicon carbide and polystyrene. The
delicate polishing process is verified to be more efficient, cost-saving, and environment friendly
than traditional processes. Their result suggest that with the increase of time, the fluidity and
stickiness of the abrasive medium improve, resulting in a finer polished surface within delicate
spiral polishing process. Their test results show an 82.44% improvement in surface roughness.
Chen and Yan (2012) employed a turning screw rod to drive the SiC and the steel grits. They
imparted magnet field around the work-piece to drive the steel grits and SiC abrasives and then
achieved the surfaces polishing effects. The results showed that the best polishing surface was
found when the magnet of magnetic flux density was controlled at 90mT, particle size at 12m,
110g of SiC grams, 60 grams of polystyrene balls, silcon oil at 1000 mm2/s viscosity, and the
screw revolution speed at 3500 rpm. The surface roughness was successfully improved from
0.9m to 0.134m.
3. Conclusions
On through analysis of the available work on Abrasive Flow Machining and its hybridization
with other non-traditional machining methods, the following conclusions have been made.
Sufficient efforts are needed to be undertaken for the improvement of AFM process
efficiency/productivity in terms of more material removal and surface finish.
More efforts needed for the optimization of process parameters from the component
quality point of view.
There are confliction opinions from the various researchers regarding the effect of some
of the variables on the response parameters.
Limitation of the traditional process to correct the form geometry is not possible with the
existing processes, requiring the development of new processes.
Hybridization of AFM has been tried for combining two or more but for some processes
this work has not been carried forward or explored further.
More, Hybrid AFM processes can be developed by using abrasives laden media which
have controllable rheology.
Still for some typical applications like, functional surface generation, form-corrections,
finishing of hard alloys or handling of delicate work-pieces, the various Hybrid AFM
processes have been found to be too sluggish and tiresome
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DR B R AMBEDKAR NATIONAL OF TECHNOLOGY JALANDHAR-144011, INDIA
DEPARTMENT OF INDUSTRIAL AND PRODUCTION ENGINEERING
IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016
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IVTH INTERNATIONAL CONFERENCE ON PRODUCTION AND INDUSTRIAL ENGINEERING, CPIE-2016
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