Published Paper Details:

Abrasive flow machining (AFM) is a popular fine finishing process for polishing hidden internal surfaces, radii and other areas of components during the current manufacturing scenario. This consists of a media containing abrasive particles forced to flow back and forth, through the workpiece under pressure, allowing for consistent finishing even in complex internal geometries. In the present study, a brass workpiece is held securely within a nylon fixture, and a two-way AFM setup is employed, where the media reciprocates between two chambers through the workpiece to achieve effective surface finishing. The abrasive-laden media typically consists of Guar gam as carriers mixed with magnetic abrasive particles and is extruded under controlled pressure. Although the process is highly effective for precision finishing, it generally has a low material removal rate and is relatively time-consuming. To improve the surface finishing of AFM, a modified technique called Electrochemical assisted Magnetic Helical Abrasive Flow Machining (ECMHAFM) was employed to finish the internal surface of a brass workpiece. The present investigation focuses on analysing the effect of electrochemical machining combined with magnetic assistance using helical profile rods on key quality characteristics, including material removal and the percentage improvement in surface roughness.