An industrially feasible approach to process optimisation of abrasive flow machining and its implementation perspectives

Abstract

This article presents a novel industrially feasible approach to ensure that an integrated optimum configuration of machine, media and geometry is achieved for abrasive flow machining process optimisation. Historically, new part introduction requires a trial-and-error phase to develop a process model, while the proposed method identifies two key explanatory variables (edge form and average roughness) and the process conditions in which they are achieved in testpiece geometry. The method and its shop-floor implementation perspectives are evaluated and verified through computational fluid dynamics simulation and well-designed machining trials, plus reapplied to more complex workpieces. The method can significantly improve abrasive flow machining process capability, accuracy and efficiency and be used to optimise machine design, attempt radical new methods of workpiece fixturing and provide an avenue to incorporate and reanalyse the adaptations of abrasive flow machining machinery.