Surface Integrity in Abrasive Flow Machining of Hardened Tool Steel AISI D2

The abrasive flow machining (AFM) is a recent manufacturing technique that uses the flow of a pressurized abrasive media for removing workpiece material. In comparison with hand polishing, AFM is very efficient process, suitable for finishing of complex surfaces. In this paper, the influence of the process parameters on surface integrity, i.e. surface roughness and induced residual stresses, is investigated. The electrical discharge pre-machined hardened tool steel AISI D2 samples have been used to be processed with AFM. Results of the work show that AFM is capable to remove EDM damaged surface and significantly improve surface roughness. Moreover, it is capable of inducing high compressive residual stresses to the machined surface, in a very thin sublayer of ∼10 μm, and so prove that AFM offers an alternative finishing process, beneficial from the surface integrity and productivity point of view.