Modeling of material removal and surface roughness in abrasive flow machining process

Abrasive flow machining process provides a high level of surface finish and close tolerances with an economically acceptable rate of surface generatio n for a wide range of industrial components. This paper deals with the theo retical investigations into the mechanism of abrasive flow machining (AFM) process. A finite element model is developed for the flow of media during A FM and the same is used to evaluate the stresses and forces developed durin g the process. Theoretical analysis to estimate the material removal and su rface roughness obtained during AFM is also proposed. The theoretical resul ts are compared with the experimental data available in the literature, and they are found to agree well. (C) 1999 Elsevier Science Ltd. All rights re served.