Nano-finishing Studies Using Elastically Dominant Polymers Blend Abrasive Flow Finishing Medium

Abrasive flow finishing (AFF) process is one of the advanced finishing processes that uses polymer rheological abrasive medium to finish simple to complex surface features. AFF process comprises of machine set-up, tooling and medium. Among these three AFF process components, medium plays an important role. Depending on medium constituents and its quantity, the rheological property as well as its finishing abilities varies. In the current research work, soft styrene polymer and silicone polymers are blended along with additives and silicon carbide abrasive particles to make medium. The viscous and elastic properties of base polymers blend are varied using softeners (stearate), plasticizers (hydrocarbon oils) and abrasive particles. Finishing experiments are conducted on Al alloy/SiC (10%) metal matrix composites using central composite rotatable design as well as the responses are modeled using response surface methodology. The best surface finish achieved with optimally blended abrasive medium on Al alloy/SiC (10%) metal matrix composite (MMC) is 110 nm.