Investigation of the effect of AFM on various machined surfaces

Deburring and surface finishing methods represent a critical and expensive segment of the overall manufacturing process. A process called abrasive flow machining (AFM) is being used to deburr, polish, radius, and remove recast layers in a wide range of applications. This paper presents the results of an investigation of the effects of AFM on surfaces produced by turning, milling, grinding, and wire electrical discharge machining. Machining characteristics studied included material removal and surface finish improvement. The statistical analysis found that the type of machining process affected both metal removal and surface finish results. Scanning electron microscope (SEM) photographs showed that AFM smoothed out the effects of the machining processes, leaving a more uniform surface. Overall, many similarities were found between grinding and abrasive flow machining. These results suggest that AFM is a very capable finishing process.