On surface texture evolution in abrasive flow machining

Abrasive Flow Machining (AFM) is highly effective for precise surface control and finishing. The process's material removal mechanism significantly impacts surface quality, especially in complex parts. However, little research addresses how initial micro-surface textures affect AFM outcomes. This study prepared four types of initial surface profiles and machined them using various abrasive media particle sizes. The rheology of the abrasive media was analyzed, with a custom guide restricting the fluid domain to create gradient flow changes. Both experimental and simulated one-way and two-way AFM processes were conducted. Results demonstrated that the material removal efficiency improved according to an enhanced version of Preston's equation for flat surfaces. Initial surface textures exerted more influence on material removal than anticipated. All abrasive media sizes yielded uniform surface quality, with surface roughness improvements exceeding 80%. Larger initial surface textures experienced greater material removal. Chemical element analysis confirmed the AFM process is contamination-free.