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Abrasive Flow Machining by Tauseef Sir
Abrasive flow machining is a finishing process that uses a viscous abrasive media to deburr and polish complex internal surfaces and passages. It can produce a smooth surface finish on difficult to access areas and remove burrs from holes and intersecting passages. The process involves extruding an abrasive media containing abrasive particles mixed in a viscoelastic polymer through fixtures surrounding the workpiece under pressure. This allows the media to flow through holes and passages to abrade away imperfections. Abrasive flow machining is commonly used in the aerospace, automotive, die and mold industries to improve surfaces, reduce wear and extend component life.
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Abrasive Flow Machining by Tauseef Sir
- 1. Abrasive Flow Machining TauseefShaikh Assistant Professor Department of Mechanical Engineering Matoshri Pratishthan’s School Of Engineering Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 1
- 2. Content 1. What isAFM? 2. Need of AFM 3. Abrasive Material 4. Mechanism of AFM 5. Components of AFM 6. Classification 1. One Way 2. Two Way 3. Orbital 7. Process input parameters 8. Application areas Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 2
- 3. Limitations of ConventionalFinishing Processes ??? Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 3
- 4. Abrasive Flow Machining •It is basically used as a deburring process. • Developed in 1960 by Extrude Hone Cooperation. • AFM can be used for; – Polish and deburr parts internally – Polish through holes – Polish intersecting holes – Calibrate fuel injection nozzles to a specific flow rates – Difficult to accesses areas – Remove scratching marks (feed marks) of other processes – radius • Uses abrasive grains mixed in a putty (a form of cement) like matrix which abrades the surface/burrs from the specific area of the material. Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 4
- 5. NEED • Smooth surfaces– Aerospace and precision components • High flow rates – Fluid dynamics and nozzles • Torque and fuel economy – Fuel nozzles and engine components • Eliminate the imperfections – Medical field Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 5
- 6. Mechanism Of AFM 1.Initially the material is ploughed by the fine abrasives which come in contact with the work material as the rub over the metal surface with high pressure. 2. The material flow occurs in the direction of the motion of abrasive particles as well as in lateral direction, resulting into the formation of the leaps. 3. The further flow of abrasive particles causes continued work hardening which results in embattlement and fragmentation of the lips into micro chips. Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 6
- 7. Mechanism of AFM TauseefShaikh, Asst. Prof., MPGI SoE Nanded 7
- 8. Components / Setup of AFM • Machine • Abrasive materials/medium • Tooling • Workpiece • Fixture plate • Fixtures • Pumping device Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 8
- 9. Machine • It determinesextent of abrasion • It is Essentially provided with 1. Hydraulic controls 2. Fixtures 3. Volume flow rate device 4. Media advance device • Its accessories are; 1. Automatic flow timer 2. Cycle timer 3. Displacement system 4. Flow control valve 5. Media heat exchanger • Standard unit operate between 10 bars to 200 bars and with flow rates of 400 lpm. Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 9
- 10. Classification of AFM 1.One way 2. Two Way 3. Orbital Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 10
- 11. One-way AFM • One-wayflow AFM processing pushes abrasive media through the work piece in only one direction, allowing the media to exit freely from the part. Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 11
- 12. Advantages of One-wayAFM • Faster cycle processing • Easy clean-up • Media temperature control generally not required • Able to process larger parts • Simpler tooling and part change-over • Accurately replicates air or liquids natural flow • Does not encapsulate work-part in media Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 12
- 13. Two-way AFM • Mostwidely used among the three. • The typical two-way flow AFM process uses two vertically opposed cylinders to extrude an abrasive media back and forth through or around passages formed by the work piece and tooling. • Abrasive action occurs wherever the media enters and passes through the most restrictive passages Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 13
- 14. Two-way AFM cont… TauseefShaikh, Asst. Prof., MPGI SoE Nanded 14
- 15. Two-way AFM(contd.) Tauseef Shaikh,Asst. Prof., MPGI SoE Nanded 15
- 16. Two-way AFM(contd.) Tauseef Shaikh,Asst. Prof., MPGI SoE Nanded 16
- 17. Advantages of Two-wayAFM • Excellent process control • Can finish both ID and OD of component • Good control of radius generation • Fully automated system capabilities • Faster setup & quick-change tooling • Faster change-over of media Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 17
- 18. Orbital AFM • Surfaceand edge finishing are achieved by rapid, low-amplitude, oscillations of the work piece relative to a self-forming elastic plastic abrasive polishing tool. • The tool is a pad or layer of abrasive-laden elastic plastic medium (similar to that used in two way abrasive flow finishing), but typically higher in viscosity and more in elastic. Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 18
- 19. Orbital AFM(contd.) Tauseef Shaikh,Asst. Prof., MPGI SoE Nanded 19 Before starting of finishing After starting of finishing
- 20. Abrasive Media • Itis the mixture of 1. Abrasive particles and 2. Elastic Polymer Elastomers • Abrasive Particles:- Generally used Abrasive particles are Aluminum oxide, silicon carbide. Boron carbides are expensive and suitable for hard materials. Silicon carbide has high stock removal rate and is both durable and economical. Diamond abrasive is used for most difficult materials like WC. It is very effective for removing thermal recast layer. • Elastic Polymer (Elastomers):- Abrasive particles are mixed with this visco-elastomers which shows change in viscosity under pressure. Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 20
- 21. Tooling • Tooling consistingof • Workpiece • Fixture plate • Fixtures • Pumping device Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 21
- 22. Machine Abrasive Workpiece Extrusionpressure Flow Volume Media flow speed Number of Cycles Medium viscosity Abrasive Concentration Abrasive type & size Restricting passage flow and area Ductile/Brittle Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 22
- 23. AFM process parameters AbrasiveBased – Abrasive grain size used in AFM varies from 500 grit (tiny hole) to 8 grit (stock removal and stocking) – Large abrasives- cut faster – Small abrasives – better surface finish as well as they can reach narrow and complex surfaces easily. Machine Based – Pressure - 0.7 Mpa to 22 Mpa (100 psi to 3200 psi) Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 23
- 24. Capabilities of AFMprocess • Surface finish in the range of 28 to 280 μm. • Hole of 0.2 mm can be made. • Dimensional tolerances achievable upto ± 0.005mm. • Can reduce surface roughness by 75 to 90% on cast, machined or EDM sufaces. Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 24
- 25. Application 1. Aerospace industry –Improved surface quality – Enhanced cycle fatigue strength – Optimized combustion and hydraulics – Increased airflow – Extended component life Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 25
- 26. Application 2. Automotive industry •Enhanced uniformity and surface quality of finished components • Increased engine performance • Increased flow velocity and volume • Improved fuel economy and reduced emissions • Extended work piece life by reducing wear and stress surfaces Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 26Grains in same direction will increase the flow rate
- 27. Application 3. Dies andmold industry • Reduced production costs • Increased production throughput • Enhanced surface uniformity, finish and cleanliness • Improved die performance and extend life of dies and molds Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 27
- 28. Application 4. Medical industry(Medical implants) • Eliminate the surface imperfections where dangerous contaminates can reside • Improved functionality, durability and reliability of medical components • Enhanced uniformity and cleanliness of surfaces, • Extended component life Tauseef Shaikh, Asst. Prof., MPGI SoE Nanded 28
- 29. THANK YOU Tauseef Shaikh,Asst. Prof., MPGI SoE Nanded 29