1

Abrasive flow machining (AFM): An Overview

M. Ravi Sankar, V. K. Jain*, J. Ramkumar

Department of Mechanical Engineering,
Indian Institute of Technology, Kanpur, 208016, India
Corresponding author: vkjain@iitk.ac.in, +91-512-259-7916


Abstract

Abrasive Flow Machining (AFM) was developed in 1960s as a method to deburr, polish, and radius difficult to
reach surfaces like intricate geometries and edges by flowing a abrasive laden viscoelastic polymer over them.
Based on the application, three different types of machines have been reported i.e, one way AFM, two way AFM
and orbital AFM. Because of simplicity in analyzing the physics, analysis of AFM process always refers to two
way AFM. It uses two vertically opposed hydraulic cylinders, which extrude medium back and forth through
passage formed by the workpiece and tooling. Abrasion occurs wherever the medium passes through the highly
restrictive passage. The key components of AFM process are the machine, tooling and abrasive medium.
Process input parameters such as extrusion pressure, number of cycles, grit composition and type, tooling and
fixture designs have impact on AFM output responses (such as surface finish and material removal). AFM is
capable to produce surface finish (Ra) as good as 0.05 m, deburr holes as small as 0.2 mm and radius edges
from 0.025 mm to 1.5mm. AFM has wide range of applications in industries such as aerospace, medical,
electronics, automotive, precision dies and moulds as a part of their manufacturing activities. For better surface
integrity, texture and its performance, continuous developments are taking place for modifying the existing AFM
process technology and AFM machine configuration. To overcome some of the draw backs such as low finishing
rate and inability to correct the form geometry, researchers have proposed various versions of AFM machines
abbreviated as M-AFM, DBGAFF, CFAAFM, spiral polishing and R-AFF.


1. Introduction

Abrasive flow machining (AFM) was developed by
Extrude Hone Corporation, USA in 1960. There are
three types of AFM machines that have been reported
in the literature: one way AFM [1], two way AFM [2]
and orbital AFM [3]. Commonly used AFM is Two-way
AFM in which two vertically opposed cylinders extrude
medium back and forth through passages formed by
the workpiece and tooling as shown in Fig.1.



Fig.1. Principle of material removal mechanism in two
way AFM process

AFM is used to deburr, radius and polish difficult
to reach surfaces by extruding an abrasive laden
polymer medium with very special rheological
properties. It is widely used finishing process to finish
complicated shapes and profiles. The polymer
abrasive medium which is used in this process,
possesses easy flowability, better self deformability
and fine abrading capability. Layer thickness of the
material removed is of the order of about 1 to 10 m.
Best surface finish that has been achieved is 50 nm
and tolerances are +/- 0.5 m. In this process tooling
plays very important role in finishing of material,
however hardly any literature is available on this () of
the process. In AFM, deburring, radiusing and
polishing are performed simultaneously in a single
operation in various areas including normally
inaccessible areas. It can produce true round radii
even on complex edges. AFM reduces surface
roughness by 75 to 90 percent on cast and machined
surfaces. It can process dozens of holes or multiple
passage parts simultaneously with uniform results.
Also air cooling holes on a turbine disk and hundreds
of holes in a combustion liner can be deburred and
radiused in a single operation. AFM maintains
flexibility and jobs which require hours of highly skilled
hand polishing can be processed in a few minutes;
AFM produces uniform, repeatable and predictable
results on an impressive range of finishing operations.
Important feature which differentiates AFM from other
finishing processes is that it is possible to control and
select the intensity and location of abrasion through
fixture design, medium selection and process
parameters. It has applications in many areas such as
Abrasive grain
Surface
roughness peak
Micro
chip
Upper medium
cylinder
Lower medium
cylinder
Abrasive
Tooling
Workpiece
Piston
2
aerospace, dies and moulds, and automotive
industries.

2. Classification of AFM machine

As mentioned earlier, AFM machines are classified
into three categories: one way AFM, two way AFM
and orbital AFM. A brief discussion of the same is
given below.

One way AFM process

One way AFM process [1] apparatus is provided with
a hydraulically actuated reciprocating piston and an
extrusion medium chamber adapted to receive and
extrude medium unidirectionally across the internal
surfaces of a workpiece having internal passages
formed therein, as shown in Fig.2. Fixture directs the
flow of the medium from the extrusion medium
chamber into the internal passages of the workpiece,
while a medium collector collects the medium as it
extrudes out from the internal passages. The
extrusion medium chamber is provided with an access
port to periodically receive medium from the collector
into extrusion medium chamber.



Fig.2. Unidirectional AFM process

The hydraulically actuated piston intermittently
withdraws from its extruding position to open the
extrusion medium chamber access port to collect the
medium in the extrusion medium chamber. When the
extrusion medium chamber is charged with the
working medium, the operation is resumed.

Two-way AFM process

Two way AFM machine [2] has two hydraulic cylinders
and two medium cylinders. The medium is extruded,
hydraulically or mechanically, from the filled chamber
to the empty chamber via the restricted passageway
through or past the workpiece surface to be abraded
(Fig.1). Typically, the medium is extruded back and
forth between the chambers for the desired fixed
number of cycles. Counter bores, recessed areas and
even blind cavities can be finished by using restrictors
or mandrels to direct the medium flow along the
surfaces to be finished.

Orbital AFM process

In orbital AFM, the workpiece is precisely oscillated in
two or three dimensions within a slow flowing pad of
compliant elastic/plastic AFM medium.

In Orbital AFM, surface and edge finishing are
achieved by rapid, low-amplitude, oscillations of the
workpiece 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.



(a)


(b)

Fig.3. Orbital AFM (a) before start of finishing, (b)
while finishing

Orbital AFM concept is to provide translational
motion to the workpiece. When workpiece with
complex geometry translates, it compressively
displaces and tangentially slides across the com-
pressed elastic plastic self-formed pad (layer of visco-
elastic abrasive medium) which is positioned on the
surface of a displacer which is roughly a mirror image
of the workpiece, plus or minus a gap accommodating
the layer of medium and a clearance.

A small orbital oscillation (0.5 to 5 mm) circular
eccentric planar oscillation is applied to the workpiece
so that, at any point in its oscillation, a portion of its
surface bumps into the medium pad, elastically com-
presses (5 to 20%) and slides across the medium as
the workpiece moves along its orbital oscillation path.
As the circular eccentric oscillation continues, different
portions of the work piece slide across the medium.
Medium
Displacer
Workpiece
Piston
Orbital
Vibrations
Piston
Hydraulic cylinder
Extrusion
medium
chamber
Workpiece
Workpiece
Flowing pad
of medium
Orbital
vibration
3
Ultimately, the full circular oscillation engages each
portion of the surface.

To assure uniformity, the highly elastic abrasive
medium must be somewhat plastic in order to be self
forming and to be continually presenting fresh
medium to the polishing gap.

For finishing applications, AFM medium allows
the use of a simple arrangement for feeding and
evacuating the abrasive medium pad to achieve
uniform results. Regions of the medium pad that
overly fill the gap generally get pushed aside and are
shaped by the oscillation of the workpiece itself.
Regions of medium in the gap that are worked
excessively become warmer, due to deformation
heating, and consequently become less elastic and
more plastic and are squeezed out of the work gap.

Orbital AFMs small (0.5 to 5 mm) oscillation
amplitude allows finishing highly complex geometries,
since all areas except internal features that are even
smaller than the oscillation amplitude are equally
worked in the process. The controlled and cushioned,
but still repeated, bumping of the workpiece against
the self-shaped tool imparts beneficial residual
compressive stresses to the workpiece surfaces. The
tangential translation of the workpiece across the
elastically compressed and cushioned abrasive
particles provides remarkable improvements in
surface roughness.

Orbital AFM can be applied to many different
workpieces from many different industries from
precision ground aerospace components to cast
aluminum wheels. Coining dies used to make proof
coins can be polished from a 0.5 m before surface to
an amazing 0.01 m after finish after only seven
minutes of Orbital AFM processing. Orbital AFM is
used to produce extremely fine finishes on the
complex geometry of prosthetic devices while
maintaining critical dimensional tolerances. Beverage
container blow molds are finished using the Orbital
AFM process dramatically reducing polishing costs
while, at the same time, improving consistency,
increasing production rates, and reducing the need for
skilled labor.

3. Major areas of experimental
research in abrasive flow finishing

3.1 Process parameters and their influence
on output responses (R
a
and MR)

Experimental investigations have been carried out by
various researchers to investigate the effects of
process parameters like extrusion pressure, number
of cycles, viscosity, abrasive concentration and grain
size on the output responses namely, surface finish
and material removal during AFM. The controllable
input parameters are shown in Fig.4.

Rhoades [4-6] experimentally investigated the
basic principle of AFM process and identified its
control parameters. He observed that when the
medium is suddenly forced through restrictive
passage then its viscosity temporarily rises.
Significant material removal is observed only when
medium is thickened. The amount of abrasion during
AFM depends on design of tooling, extrusion
pressure, medium viscosity and medium flow volume.
All these parameters ultimately change the number of
particles interacting with the workpiece and the force
acting on individual abrasive grain. A higher volume of
medium flow increases number of interacting abrasive
grains with the workpiece, hence more abrasion takes
place. Number of cycles depend on the velocity of
medium, during a given time period. Flow pattern of
medium depends on its slug (medium exiting the
workpiece) flow speed, medium rheology and
passage size (cross-sectional area). AFM can be
used in industrial applications such as precision
deburring, edge contouring, surface finish, removal of
thermal recast layers, etc. [7].

Williams and Rajurkar [8] used the full factorial
experimental design to study the effect of medium
viscosity and extrusion pressure on metal removal
and surface roughness. Mediums viscosity effect is
more significant on material removal as compared to
extrusion pressure. It is also reported that major
change in the surface finish is observed after finishing
for a few cycle only.

Jain and Adsul [9] reported that initial surface
roughness and hardness of the workpiece affects
material removal during AFM process. Material
removal and reduction in surface roughness value are
reported higher for the case of softer workpiece
material as compared to harder material. Material
removal and reduction in surface roughness increases
when percentage concentration of abrasive in the
medium increases. They also concluded that among
all the process parameters studied, the dominating
one is the abrasive concentration followed by abrasive
mesh size, and number of cycles.

Loveless [10] reported that the type of machining
operation used to prepare the specimen prior to AFM
is important and affects the improvement achieved
during finishing. As compared to the turned and milled
surfaces, WEDMd surfaces are found to be more
suitable for AFM. The amounts of material removal
from the WEDMd and milled surfaces are significantly
different from that of turning and grinding, because
these machining processes produce different micro
surface contours.

Davies and Fletcher [11] reported a relationship
between the number of cycles, temperature and
pressure drop across the die for the given type of
polymer and abrasive concentration. Increase in
temperature results in decrease in medium viscosity
and increase in volumetric flow rate. With increase in
processing time, medium temperature increases that
causes a change in medium viscosity. They
concluded that rise in temperature is due to a
combination of internal shearing of the medium and
finishing action of the abrasive grit.

4





























Fig. 4 Classification of major AFM research areas
AFM
Research areas
AFM
Applications
Types of
AFM Machine
AFM
Monitoring
AFM
Theoretical models
One way
AFM
Orbital
AFM
AFM Performance
measures
Surface
Roughness
Material
removal
Finishing
Forces
Active Grain
AFM Process
Parameters
Medium
Parameters
Machine
parameters

Abrasive
Type
Abrasive
Concentration
Abrasive
Size
Workpiece
Parameters
Initial
Surface
Material
Hardness
Material
Type
Passage
Geometry
Two way
AFM
Number
of cycles
Extrusion
Pressure
Polymer Type and
concentration
Additives
5
3.2 Process modeling and optimization

Williams and Rajurkar [12] developed a stochastic
model of AFM generated surfaces by using Data
Dependent Systems (DDS) methodology. They have
estimated the ratio of surface roughness peak to
valley height (Rz) to centerline average surface
roughness value (Ra) by DDS methodology and found
to be between 1.4 and 2.2 for the AFM process. It was
established in their research that AFM finished
surface profiles possess two distinct wavelengths, a
large wavelength that corresponds to the main path of
abrasive while the small wavelength is associated
with the cutting edges. Good agreement is found
between the primary frequency ranges obtained in
DDS modeling and those derived from spectral
analysis function. It is stated that these frequency
bands are related to different material removal modes
in AFM; consequently, the mechanism of material
removal in AFM is considered to consist of ploughing
responsible for creation of characteristic flow lines and
micro-cutting. They also proposed an expression for
estimating the abrasive grain wear and the number of
active grains (Cd). The estimated value of Cd is used
as a cutting life criterion for abrasives. For small
number of cycles its value should remain fairly stable
but with more and more processing the abrasive
particles may fracture thereby increasing the Cd value.
The downturn of Cd value indicates that the medium
has absorbed too much work piece material and need
replacement. Jain et al. [13] also carried out
simulation of finished surface profile and material
removed considering the interaction of abrasive grains
with workpiece.

Rajeshwar et al. [14] proposed a mathematical
simulation model to determine the characteristics of
the medium flow during finishing and its experimental
verification was carried out. This model was
developed using constitutive equations of Maxwell
model considering the medium characteristics as non-
newtonian flow. They reported that a linear
relationship exists between shear stress acting on the
surface and the layer thickness of material removed.

A finite element approach was developed by Jain
et. al. [13] for prediction of the stresses developed
during finishing of a cylindrical passage by AFM
process (axi-symmetric flow). In their study it is
assumed that medium exhibits linear viscous flow
property and medium properties are independent of
temperature and are constant with regards to time
and space. They also presented a theoretical model
which is based upon the consideration that abrasion
process in AFM i.e., combination of micro-ploughing
and micro-cutting by assuming that all the abrasive
particles are spherical in shape having a single cutting
edge with same size. It is also assumed in this model
that the load acting on each particle is constant and
every grain achieves the same penetration depth
depending upon applied load.

Gorana et. al. [15] developed a theoretical model
of forces acting on a single abrasive grain for studying
the finishing mechanism of AFM process. Comparison
of theoretical model results with that of experimental
data of force and active abrasive grains density
obtained during AFM process was done.

Fletcher et al. [16] studied the relationship
between medium rheological properties and the AFM
process. Shear rate of the polymer increases when it
passes through the restriction (or reduced cross-
sectional area). Capillary rheometer is used to find the
relationship between wall shear stress and shear rate
for medium viscosity of polyborosiloxane medium.
They concluded that coefficient of viscosity decreases
but shear stress increases as shear rate increases.
Variation of wall shear stress with time is also studied.
They also concluded that greater finishing action
could be achieved as a result of longer piston stroke
durations, due to higher wall shear stress generated.

Petri et.al., [17] adopted neural network modeling
technique for developing a comprehensive model for
AFM. They presented three neural network models
(Polishing applications, surface removal applications
with a circular flow path and surface removal
application with a non circular flow path). Kimbly et al.
[18] reported a set of neural network models that
predict the surface finish and dimensional change.
These neural network models are then paired with a
heuristic search algorithm to select sets of machine
setup parameters for the AFM process. Lam and
Smith [19-20] applied Cascade-Correlation neural
network modeling to finishing of automotive engine air
intake manifold. They used it to predict the instant at
which the finishing process should terminate to meet
the airflow specifications.

Jain and Jain [21] proposed a generalized back-
propagation neural network model and a second
network which parallelizes the augmented Lagrange
multiplier (ALM) algorithm. The model determines
optimal finishing parameters by minimizing a
performance index subject to appropriate operating
constraints. Sarah et al. [22] presented a neural
network model as an off-line controller for AFM of
automotive engine manifold to predict when the AFM
process should be stopped to achieve the required
airflow rate through manifold body.

3.3 Monitoring of AFM process

For online monitoring of material removal and surface
roughness in AFM process, Williams and Rajurkar
[23] applied acoustic emission technique (elastic
stress waves generated by the rapid release of strain
energy within a material due to a rearrangement of its
internal structure is called "acoustic emission"). In a
full factorial experiment, the effect of extrusion
pressure, medium viscosity, abrasive grit size,
number of cycles, and work piece material was
investigated on material removal, root mean square of
acoustic emission signal (AERMS), and surface
roughness improvement. From the above parameters
only grit size showed insignificant affect on material
removal. They studied acoustic emission signals for
grinding to analyze the mechanism involved in AFM
and found that the acoustic emission signal is highly
dependent on the characteristics of the initial surface
roughness of the workpiece. The AERMS of the signal
is sensitive to extrusion pressure and other AFM
process parameters, which affect material removal.
6
They used Data Dependent Systems technique to
analyze the acoustic emission signal acquired during
AFM processing. In DDS analysis, they found that
main root of frequency of signal was around 160 kHz
and secondary root with less power had a frequency
around 80-90 kHz. They reported the fact that the
higher frequency component is associated with the
ploughing mechanism which would agree with the
results obtained during grinding. They also found that
aluminum workpiece give stronger signals than steel
workpiece because of higher material removal from
aluminum workpiece as compared to steel under
identical finishing conditions. This suggests a strong
correlation between material removal rate and
acoustic signal in AFM.

3.4 Recent developments in AFM processes

Though there are many advantages of AFM process,
it has a few disadvantages also, such as low finishing
rate, and incapability to correct the form geometry.
Many researchers have been working to improve the
finishing rate, surface integrity and compressive
residual stresses produced on the workpiece surface.

Singh and Shan [24] applied magnetic field
around the workpiece in AFM and observed that
magnetic field significantly affect the material removal
and change in surface roughness. With the
application of magnetic field, less number of cycles
are required for the higher material removal. Higher
material removal and higher change in surface
roughness are observed (in case of brass as
workpiece material) with the low flow rates of medium
and high magnetic flux density.



Fig.5. Sectional front view of tooling in the finishing
region in DBG-AFF process and top view of medium
splitting through twin slotted fixture plate [25].


Ravi Sankar et.al., [25] tried to improve finishing rate,
material removal and surface texture by placing drill
bit in the medium flow path called Drill Bit Guided
Abrasive Flow Finishing (DBG-AFF) (Fig.5). 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 interact with the workpiece surface.
From the experimental results, it is concluded that the
abrasive traverse path is longer than the AFM
abrasive traverse path in each cycle. It results in
higher finishing rate in DBG-AFF as compared to
AFM. Material removal is found to decrease with
decrease in drill bit diameter.

Biing-Hwa Yan et. al., [26] placed spiral fluted
screw in the medium flowing path to improve surface
quality. Walia et. al., [27] rotated different shaped tiny
rods at the centre of the medium flow path and used a
low viscosity medium to finish. He concluded that the
better surface finish is achieved due to centrifugal
action caused by the rod on the abrasives and this
process is called centrifugal force assisted abrasive
flow machining (CFAAFM). But all these three rotating
medium methods may rotate the medium at and near
the axis of the medium but the probability of rotating
the medium at the abrasive-workpiece interaction
region is very low. Ravi Sankar et. al [28] developed a
new set-up to rotate the workpiece so that the
probability of active abrasive particle rotation in the
workpiece finishing region is high which improves
both surface finishing rate and material removal rate.
The process physics and various forces acting on the
work surface due to medium reciprocation, rotation of
workpiece and viscoelastic nature of medium are
shown in Fig.6. The force and velocity components of
R-AFF process in the finishing region are illustrated in
Fig.6. During R-AFF process, the rotational workpiece
motion leads to a tangential velocity component Vt
and medium reciprocation motion leads to an axial
velocity component (Va). The resultant finishing
velocity (Vc) in R-AFF (Fig.6(a), Fig.6(c)) is the vector
sum of Vt and Va. Theoretically, the direction of Vc is
at the semi-cross hatch angle () to the tangential
motion.

Where,
1
tan ( )
a
t
V
V

=

Since, the abrasive laden medium is semisolid,
the finishing lay wont be exactly in direction.
Depth of indentation depends on
r
F , while
a
F and
t
F (
2 2
c a t
F F F = + ) are responsible to remove the
material in the form of -chips. Where, Fa represents
axial force, Ft represents tangential force, Fr
represents radial force and Fc and Ff gives the
resultant forces in 2-D and 3-D planes respectively.




A A
Workpiece
Drill bit
Fixture plate
Piston
Cylinder
Fixture
Medium
Slot in the
fixture plate
Fixture plate
7

(a) (b) (c)

Fig.6. Forces and velocity components in R-AFF process in the finishing region (a) Overview of various forces
and velocities in workpiece, (b) Enlarged view of shearing of roughness peaks on the workpiece surface by
abrasive grains, (c) Free body diagram of forces and velocities in RAFF process [28].



Fig. 7: Surface finish improvement before and after on (a) internal passages within turbine engine diffuser (b)
Medical implants (c) complex automotive engine parts








Before AFM







After AFM

Fig. 8: Photomicrograph showing complete removal of EDM recast layer


4. Application of AFM

4.1 Automotives

The demand for this process is increasing among car
and two wheeler manufacturers as it is capable to
make the surfaces smoother for improved air flow and
better performance. AFM process is used to enhance
the performance of high-speed automotive engines.
AFM process is capable to finish automotive and
medical parts, and turbine engine components [Fig.7].
Internal passages within a turbine engine diffuser are
polished to increase air flow to the combustion
chamber of the engine. The rough, power robbing
cast surfaces are improved from 80-90% regardless
of surface complexities.

4.2 Dies and Moulds

Since in the AFM process, abrading medium
conforms to the passage geometry, complex shapes
can be finished with ease. Dies are ideal workpieces
for the AFM process as they provide the restriction for
medium flow, typically eliminating fixturing
F
a
, V
a

F
t
, V
t

Fr
F
c
, V
c


F
t
, V
t

F
r

F
a
, V
a

F
f

F
c
, V
c


Before
AFM
After AFM
Before
AFM
After AFM
8
requirements. The uniformity of stock removal by
AFM permits accurate 'sizing' of undersized precision
die passages.

The original 2m Ra (EDM finish) is improved to
0.2m with a stock removal of (EDM recast layer)
0.025mm per surface (Fig. 8).

5. Concluding remarks

AFM is a well established advanced finishing process
capable of meeting the diverse finishing requirements
from various sectors of applications like aerospace,
medical and automobile. It is commonly applied to
finish complex shapes for better surface roughness
values and tight tolerances. But the major
disadvantage of this process is low finishing rate. So
continuous efforts are being made to increase
finishing rate, improve surface texture and to some
extend to improve MRR. To achieve an accurate and
efficient finishing operation without compromising the
finishing performance, understanding of inter
relationship between various input parameters and
output responses that influence the process
performance. This leads to identification of various
optimal finishing conditions from the infinite number of
combinations and their modelling. The better
performance is achieved if the process is monitored
online. So, acoustic emission technique is tried to
monitor the surface finish and material removal but
ended with only marginal improvement. Later various
modelling techniques (mathematical, analytical and
empirical) are used to model this process to correlate
with experimental results. To overcome the
disadvantages of the process, many modifications (M-
AFM, CFAAFM, DBGAFF, R-AFF and spiral polishing
method) have been tried. But in spiral polishing,
CFAAFM and DBGAFF processes, the probability of
role of additional tooling which is at the middle of the
slug has less influence on the finishing direction of
active abrasive grain. But later this problem is solved
by rotating the workpiece itself. It makes the active
abrasive grains to follow helical path, which improves
the contact length of the active abrasive grain with
workpiece. In R-AFF process, better improvement in
surface roughness is achieved compared to AFM and
takes lesser time to achieve same surface finish that
can be achieved through AFM process. But authors
feel that there is still room for lot of improvements in
the present AFM status.

Acknowledgement

The authors acknowledge the financial support
provided by the Aeronautics R & D Board, New Delhi,
for Project No. DARO/08/1161387/M/I, entitled as
Finishing of Miniature Holes in Super Alloys using
Abrasive Flow Machining (AFM).

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th
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th
, 1991.
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International patent no: WO 90/05044, 17
th

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