Module-3: ADVANCED MATERIAL REMOVAL PROCESSES

Lecture No-2

Mechanism and Process Parameters in AFM

The mechanism of material removal in AFM is as follows:

1. Initially, the material is ploughed by the fine abrasives that come in contact with
the work material as they rub over the metal surface with high pressure. The
material flow occurs in the direction of motion of abrasive particles as well as in
lateral direction, resulting into the formation of lips.
2. At the lips, work hardening is noticed due to the rubbing action of the continuous
flowing abrasive particles which are also responsible for intense plastic flow with
considerable stress concentration.
3. The further flow of abrasive particle causes continued work hardening which
results in embrittlement and fragmentation of the lips into microchips.

AFM Process Parameters

The AFM Process Parameters are classified as given below:

 Parameters controllable by the machine: extrusion pressure, flow volume, media flow
speed and number of process cycles.
 Parameters controllable by the media: media viscosity, media rheology, abrasive type
(aluminum oxide, silicon carbide, boron carbide, diamond etc.), abrasive grain size,
shape and concentration.
 Parameters controllable by the work piece configuration and tooling: type of passage
(cylindrical, rectangular or complex), cross sectional area, length of the passage,
initial surface roughness.
An
A Ishikawaa cause and
d effect diag
gram as shoownin Fig.33.2.1, identiifies the process
parameters affecting
a thee quality off the machinned surfacess in AFM process. A brief
description off some impo
ortant processs parameterss of AFM is as follows:

Work piece

Media
M Flow Volume and
d Extrusion
n Pressure

These
T are th
he dominant process paarameters coontrolling thhe amount oof abrasion by a
sp
pecific mediia compositiion. With alll other factoors constantt, a greater vvolume of m
media
will
w cause mo
ore abrasion
n. If two passsages of diff
fferent cross--sectional arreas are giveen the
saame volumee of flow, thee smaller paassage will thherefore be abraded morre than the llarger
passage.

Extrusion
E preessure stron
ngly affects the final foorce acting oon abrasive grains andd thus
siignificantly affects
a the su
urface rough
hness of the machined paart.
Media Flow Rate

The literature on AFM strongly recommends that the affect of flow rate of media is not
significant.
Media Viscosity

Viscosity of media is the significant parameter affecting the quality of surface finish and
amount of material removal in AFM process. Media viscosity is affected by type of
abrasives, its concentration and size of grains. It is also strongly affected by the working
temperatures. In general, increase in temperature causes appreciable decrease in media
viscosity, which may result in ‘settling’ of grains thereby influencing the flow properties
and overall abrasion process. Table 3.2.1 gives general guidelines to select viscosity of
media for various passageways with 2:1 length to width ratio.

Table 3.2.1 The Guidelines for Media Selection

Passage Media Viscosity

size* (mm)
Low Low/Medium Medium High/Medium High
Minimum 0.4 0.8 1.6 3.2 6.4
Maximum 3.2 6.4 12.8 25.4 50.8

* Passage sizes are widths or diameters of the cavity and assume that the passage length
is two times the width.

Number of Cycles

The travel of media from lower cylinder to upper cylinder and then back to lower
cylinder is termed as a cycle. Several cycles are required to get a particular amount of
material removal and final surface finish on a component. Various researchers have
reported that the improvement in surface finish and required amount of material removal
occurs in some of the initial cycles and then it stabilizes.

Abrasive Grain Size and Its Concentration

Abrasive grain sizes range used in AFM varies from #500 grit (tiny hole applications) to
#8 grit (roughing and stock removal applications). Larger abrasives cut faster, while
smaller size gives better finish and can reach into complex and narrow passages.

AFM Process Capabilities

The surface finish improvement by AFM process is 10 times than that of the original
surface finish, provided the surface finish is in the range of 28-280 m. Holes diameter
must be at least 0.2 mm and dimensional tolerances achievable must be up to ± 0.005
mm.

Recent Developments in AFM Technology

Ultrasonic Flow Polishing

Ultrasonic Flow Polishing (UFP) is the combination of AFM and USM. In this process,
the abrasive/polymer mixture is pumped down the centre of the ultrasonically energized
tool. On its exit, the flow is constrained by the tool and the work piece, the mixture flows
radially relative to the axis of the tool. While it is constrained, the vibrating tool
ultrasonically energizes the mixture. The combination of flow and vibration results in the
effective abrasion of the workpiece surface. The process is reported to have the capacity
to produce micro/nano level finish on closed cavity surfaces without causing much
deterioration to its profile or dimensional accuracy. The improvement in surface finish of
upto 10:1 is been reported by this process. The Ultrasonic flow polishing process is very
much suitable for applications in machining blind cavities that are not easily polishable
by normal AFM.

Orbital AFM

Orbital AFM combines abrasive flow machining and orbital grinding. An additional
mechanical motion is given to the medium to enable it polish three dimensional forms
that are not possible with conventional AFM. The motion is typically a planetary
oscillation that creates relative displacement between tooling and the work piece. The
oscillations can be in the vertical or horizontal or combination of both the planes,
yielding an elliptical or gyratory polishing action. Orbital Polishing is made used in
polishing the edges and surfaces in complex shapes and cavities such as bottle molds,
coining dies and aluminum wheels along with high precision and accuracy.

Magneto Abrasive Flow Machining

Magneto Abrasive Flow machining process has been developed by providing a magnetic
assistance to the flowing abrasives. Through this additional assistance, modification of
the distribution pattern of abrasive particles near to the inner surface of the hollow work
piece has been observed. Therefore, more number of abrasive particles could take part in
the abrasion process. In addition, some of the axially flowing abrasive particles get
deflected and strike on the work piece surface a slight incidence angle. On an average,
20-30 % enhancement in the material removal rate along with considerable
improvements in the finish has been recorded depending upon the material of the work
piece particularly at low flow rates of the media.

Centrifugal Force Assisted AFM

A controlled rotation of a centrally placed rod in flow passage generates the centrifugal
forces in the flowing media. This force increases the media contact force to the work
piece as the media flows through the work piece cavity due to the extrusion pressure. It is
compounded upon by the centrifugal force. The combined effect of these two forces
improves the contact of the abrasive particles with the work piece surface. In this process,
a special type of nylon fixture is used to hold the work piece that is placed in between the
two media cylinders in-order to create an artificial dead zone and increase the pressure
required for extruding the media