Review of surface roughness and material removing rate on abrasive flow machining process

. Every day, advancements in manufacturing technology research and innovation yield a highly finished surface with lower labour and machining costs. The conventional materials that were frequently employed in the chemical, automotive, and aerospace industries have been replaced by materials like ceramics, metal matrix composites, polymers, and super alloys. The AFM technology is capable of maintaining precision, reliability, and adaptability across adverse range of applications. Internal parts, through holes, intersecting holes, and freeform surfaces that are challenging to finish with other conventional finishing techniques can all be polished and deburred with AFM. The current study aims to determine the process variables that have a major impact on the change in surface roughness of the inner, outer, and side surfaces as well as the amount of material removal. These parameters include abrasive mesh size, abrasive concentration in media, and the number of passes. A review of published technical articles on the AFM process is attempted in this article, and the studies are divided into four categories: experimental setups, abrasive media, modelling and optimisation, and applications of the AFM process. The review article provides fresh directions for future investigation. Page layout


Introduction
In recent decades, both conventional and unconventional finishing techniques, including but not limited to refining, splashing, and grinding, have Bg" employed by markets to achieve the intended level of machining finishing components.But conventional techniques specific geometric models for achieving desirable throughout process.The insufficiencies of conventional finishing techniques have prompted finishing including Abrasive Flow Machining (AFM) Hiremath, 2016).The utilization of Atomic Force Microscopy (AFM) is development of processes, (Kumar and the utilisation of widely recognised as a nonconventional technique that holds significant potential in surface refinement, precision deburring, radioing, and the removal of the recast layers The AFM technique exhibits the capacity to effectively enhance the visibility of complex, difficult-to-reach the study of geometry.The AFM process involves the utilisation of tooling, machining, and abrasive media (Rhoades, 1991).The equipment utilised in this process comprises of two media cylinders that are positioned in and are through a opposition to each other subjected to refinement "power pack assembly."During the machining process, tooling crutches are utilised to enhance the work surface and facilitate the timely completion of the abrasive media area.Furthermore, the employment of rough media, comprising of materials based on polymers and abrasive particles is employed as a means of achieving the desired surface finish (Singh & Sankar, 2019).In this particular methodology, the coarse media is removed through a narrow and restricted passage that exists between the tooling and the work surface resulting in abrasion of the work area.The process of material removal is accomplished through the utilisation of three distinct modes, namely micro-poling, free massaging, documented by Kum et al. ( 2020) and The generation of fresh surfaces during the and microcutting, as abrasive machining procedure is a result of the indiscriminate assault of abrasive constituents on surface irregularities, which impel the workpiece surface.This been noted in previous studies (Walia, Shan, & Kumar, 2009;Ali et al., 2020).The application of hydraulic cylinders to generate extrusion pressure results 2s production of both regular pressure and axial force on the above components.Moreover, as per Lin et al. (2020), the normal force penetrates the abrasive material in opposition to the applied labour force.Meanwhile, the axial component generates the necessary axial motion to facilitate the penetration of the abrasive material and eliminate the contaminants from the work surface.The phenomenon of "micro ploughing" and micro-cutting" occurs concurrently in flexible materials, but the latter is deemed to be more prevalent in brittle materials.
The parametric assessment and analysis of the AFM technique is widely regarded as a crucial area of exploration within the field of AFM.The AFM reactions encompassing microhardness, surface finishing, product elimination, wettability, and residual stress are subject to the influence of various interdependent factors Be parameters, including those that are media-based, machine-based, or variant-based.The parameters on media is frequently performed.The mechanical printed PLA components have been investigated by properties of 3D Jayakumar et al.The authors have i an analysis on the influence of printing procedure specifications, specifically infill, thickness (%), nozzle temperature (°), and print alignment, as documented in their recent publication et al., 2021).The authors Mohamed ct al. ha a study to examine product usage in the context of integrated deposition modelling.The optimisation of process criteria has been carried out by the writers through the implementation of the reaction surface method (RSM) strategy, as reported by Mohamed et al. (2015).The tribological behaviour of 3D printed ABS com nts was investigated by Kumar  All machines, regardless of size, are hydraulic systems with positive displacement that push media loaded with abrasives through the fixture workpiece at a predetermined pressure and flow rate.AFM systems that are standard operate at 0 and 200 bars and at up to 400 litres per minute.Controls for hydraulic system pressure, media volume flow rate, fixture clamping and unclamping, and media piston advance and retract are essentially included in AFM systems.Typical AFM systems for industrial applications are combined with accessories like temperature-and pressure-compensated flow control valves, volumetric displacement systems, automatic flow timers, cycle counters, and media heat exchangers.For many uses, silicon carbide and aluminium oxide make the best abrasives; however, diamond and boron carbide are reserved for certain uses.The ratio of abrasive grain to base material can range from two to twelve.In order to achieve the appropriate flowability and rheological qualities for the medium, the additives are mostly utilised to alter the properties of the base material.

Types of Abrasive Flow Marching Process:
Generally abrasive flow matching process are 1) One-way abrasive flow matching process 2) Two-way matching process, 3) Orbital machining process Recently Developed principal of gas-solid two-phase flow finishing [] as shown Investigating a surface roughness prediction model for gas solid two-phase abrasive flow machining is the primary goal of this work.To accomplish the aforementioned goal, an orthogonal experiment was conducted.In the experiment, white corundum with varying particle sizes was utilised as an abrasive material and Q235 steel as the processing material.The primary reference factors were shape and spindle speed.[12] Fig. 4. Shows gas solid II phase flow finishing [12] , 01032 (2024) MATEC Web of Conferences https://doi.org/10.1051/matecconf/202439201032392 ICMED 2024 Fig. 5. Principal of gas solid II phase flow finishing Figure 4 depicts the experiment employing a self-made gas-solid two-phase flow abrasive pool processing setup.This experiment used a self-made abrasive pool processing platform that combines solid-phase abrasives with gas to create gas-solid two-phase flows with varying flow states.The gas-solid two-phase flow allows the abrasive to contact, rub, and collide with the workpiece surface, micro-cutting it to finish it.Figure 5 depicts the gas-solid, two-phase flow abrasive pool finishing process.Abrasive flow machining process with rotation mechanism and control system is another new techniques which is HC system to fix workpiece and medial flow in reciprocating motion control by control unit as show in fig 6 Fig. 6.Shows Abrasive flow machining process with rotation mechanism and control system [6] , 01032 (2024) MATEC Web of Conferences https://doi.org/10.1051/matecconf/202439201032392 ICMED 2024 As seen in Figure 6, the planned fixture was created using SolidWorks software and includes a gearbox gear, a passive gear, an upper and lower fixed block, an upper and lower tool and an bearings on the upper and lower ends.The components of the upper tool and upper fixed block were locked on the upper barrel, while the lower tool and lower fixed block were fastened together on the lower barrel.The transmitted gear was driven by a servo DC motor, and there was a 1:5 gear tooth ratio between the transmitted and passive gears.By encircling the workpiece in a magnetic field, invented the Magneto Abrasive Flow Machining (MAFM) technique, which increases material removal rate and decreases surface roughness.The most important factors, such as the abrasive grit size, abrasive concentration, number of cycles, medium flow volume, magnetic flux density, volume flow rate, and reduction ratios, were determined using the ANOVA technique.MAFM exhibits better MRR and surface polish than AFM.Walia et al. [15] attempted to increase the efficiency of the AFM process by exerting centrifugal exertion on the rough surfaces.As illustrated in Fig. 10, the procedure is known as Centrifugal (CFAAFM).They have reached a conclusion.11.Shows line illustration of ECAFM [16].Fig. 12 Shows line illustration of R-AFF [17] 3 Application of Abrasive flow machining Process: MEMS component machining: The fundamental components of microfluidic technology are micro channels.The recast layer in the machined area is formed by the electron discharge machining method, which is frequently employed to create microchannels.A self-modulating abrasive media was created by Tzeng et al. [18] to eliminate the recast layer from the microchannels created by wire-EDM.They have reached a conclusion.industrial component machining: Bevel gear is employed in a wide range of applications, including railway tracks, locomotives, rotorcraft drives, vehicle differential drives, and maritime applications.Typically, casting procedures or traditional gear cutting techniques are used to create these gears.In many machining shops, finishing gears after they have been manufactured is a difficult operation.The Ultrasonically Assisted Abrasive Flow Machining (UAAFM) technology was established by Venkatesh et al. [19] to achieve the highest level of polish on bevel gears.In order to enhance the surface finish of bevel gears, input variables such as time, media flows, extrusion pressure, and ultrasonic frequency were taken into consideration.AFM technique was utilised by Li et al. [20] to enhance Biomedical component manufacturing: In the biomedical, aerospace, turbine blade, automotive, and optical components industries, freeform surfaces are frequently employed.Advanced CNC machines, casting, and fast prototyping are frequently used to create these surfaces.Finishing these surfaces to a higher standard after machining is a challenging operation, and numerous researchers have developed various finishing processes.Sidpara et al.
[21] used a magnetorheological fluid-based finishing tool to complete a knee joint implant.(R-MRAFF) was developed by Kumar et al. [22] to finish freeform components to the nanoscale level, akin to knee joint implants.

Conclusions:
This method works well for finishing components with complex profiles that are mostly utilised in the biomedical, aerospace, and automotive industries.Methods for modelling and optimisation are created and used to the analysis of the MRR and Surface finish output reactions.ANOVA, Taguchi, Central composite design, neural network, GMDH and pareto based optimisation approaches, mathematical, and FEM techniques are the most often utilised methods The study includes details on some of the produced experimental settings by different experts.The following are some examples of abrasive flow finishing techniques: Drill Bit Guided-Abrasive Flow Finishing (DBG-AFF); Rotational-Abrasive Flow Finishing (R-AFF); Centrifugal Force Assisted Abrasive Flow Machining (CFAAFM); Electro-Chemical aided Abrasive Flow Machining (ECAFM); Drill Bit Guided-Abrasive Flow Finishing (D-AFF); Rotational-Abrasive Flow Finishing (R-AFF); and Rotational Magnetorheological Abrasive Flow Finishing (R-MRAFF).A review of published technical articles on the AFM process is attempted in this article, and the studies are divided into four categories: experimental setups, abrasive media, modelling and optimisation, and applications of the AFM process.

Fig. 3 .Fig. 4 .
Fig. 3. Shows One-way AFM and Two-Way AFM Mostly used orbital Abrasive Marching Process because here abrasive media force act in reciprocal motion