Effect of Operating Parameters on the Performance of Abrasive Flow Machining Process

Abrasive flow machining (AFM) process can be applied to an impressive range of machining operations, providing uniform, repeatable and predictable results, higher productivity and automatic operation. AFM experiments on mild steel workpieces using SiC abrasive mixed with polyborosiloxane carrier indicate that the required surface finish on the workpiece can be achieved by controlling AFM process parameters. Central composite rotatable design has been used to study the effects of four important process parameters on process performance. An increase in extrusion pressure increases both the depth of indentation as well as medium velocity. Increase in percentage concentration of abrasives increases active grains density. It is concluded that material removal and change in surface roughness (ΔRa) are higher at higher extrusion pressure and higher abrasive concentration. Material removal and change in surface finish also increase with increase in reduction ratio and number of cycles.