Investigations into abrasive flow finishing of complex workpieces using FEM

Abrasive flow machining (AFM) process provides a high level of surface finish and close tolerances with an economically acceptable rate of surface generation for a wide range of industrial components. It is attempted to analyze the AFM process using finite element method (FEM) for finishing of external surfaces. To study the material removal mechanism of AFM, finite element model of forces acting on a single grain has been developed. Response surface method (RSM) is used to carry out an experimental research to analyze the effect of extrusion pressure and number of cycles on material removal and surface finish. Results obtained from finite element analysis for material removal have been compared with the experimental data obtained during AFM.