Rotational abrasive flow finishing (R-AFF) process and its effects on finished surface topography

The present study focus on abrasive flow finishing (AFF), a process that finishes complex internal and external geometries with the help of viscoelastic abrasive medium, while keeping in mind its low finish and material removal rates (MRR). Researchers have often strived to improve finishing rate and MRR. As an attempt to overcome the said limitations, this paper discusses rotational abrasive flow finishing (R-AFF) process wherein complete tooling is externally rotated and the medium reciprocates with the help of hydraulic actuators. In this study, preliminary experiments are conducted on Al alloy and Al alloy/SiC metal matrix composites (MMCs) at different extrusion pressures, and medium compositions are employed for finding optimum conditions of the same for higher change in roughness (ΔRa). The same optimum conditions are used to study the effect of workpiece rotational speed on (ΔRa), material removal (MR), change in workpiece hardness and surface topology. It is noted that as the workpiece rotational speed increases from 2 to 10 RPM, the experimental helix angle decreases from 22° to 9° and the helical path length increases from 67 to 160 mm. Based on these findings the mechanism of material removal of matrix and reinforcement in MMC using R-AFF have been proposed. Here the matrix material is removed by micro-cutting and three methods of material removal mechanisms for reinforcement are also explained. The scientific logic behind finishing mechanism of matrix and reinforcement, cross hatch patterns, helical path directions, micro-scratch (μ-scratch) width and depth variation with size, orientation and support that active abrasive grain obtains from neighboring abrasives is derived from scanning electron microscopy micrographs. Finally this study establishes that R-AFF can produce 44% better ΔRa and 81.8% more MR compared to the AFF process. Accordingly, R-AFF generates micro cross hatch pattern on the finished surface that can improve lubricant holding capabilities.