Developing a Process Model for Abrasive Flow Machining

Abrasive flow machining (AFM) is a unique machining method used to achieve high surface quality on inner, difficult-to-access contours and on outside edges. Using AFM, it is possible to deburr complex shaped intersecting holes and to realize pre-defined edge rounding on any brittle or hard material. Moreover it is easy to integrate into an automated manufacturing environment. Reproducibility of results saves various time and cost consuming manual operations in industrial applications. However for an implementation in new applications costly and time-consuming preliminary investigations are required that have to be carried out by trained staff. Therefore the aim of recent research activities is to identify the fundamentals of the process, the functional correlations between setting parameters and work results. This paper presents an approach using a numerical simulation to develop a process model. Furthermore a model is introduced that describes the fundamental principles of the deburring process using AFM.