Experimental investigations into ultrasonic-assisted abrasive flow machining (UAAFM) process

Ultrasonic-assisted abrasive flow machining (UAAFM) process is being investigated as an effective variant of traditional abrasive flow machining process. This process aims to achieve better surface finish at higher finishing rate. In this process, a relatively high frequency (5–20 kHz) is provided to the workpiece externally using a piezo actuator. This additional effect is also termed as ultrasonic assistance. Owing to this, the abrasives present in the medium hit the workpiece asperities mostly at an angle and at a higher resultant velocity, thereby making them more effective. In the present work, experiments were conducted on EN8 steels (AISI 1040) to evaluate the process performance of UAAFM on the double acting horizontal type setup. Response surface methodology (RSM) technique was used for designing the experimental plan with four input parameters—applied frequency, extrusion pressure, abrasive mesh size, and processing time. The results obtained after machining by UAAFM were also compared with traditional AFM process. It was found that significant improvements in surface finish could be recorded in UAAFM. The maximum percentage improvement achieved in surface finish was 81.02 %, while maximum improvement in material removal was 0.05 %. The machined surfaces were also investigated using different characterization tools such as scanning electron microscope (SEM), X-ray diffractometer, and three-dimensional optical profilometer.