Optimized and accelerated process design and control in industrial Abrasive Flow Machining through numeric process models and better understanding of the process fundamentals

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Abrasive Flow Machining is a process used to machine complexly shaped and hard-to-reach inner and outer contours of parts. Because of its inherently low material removal rates, Abrasive Flow Machining is solely used for surface quality improvement, edge rounding and deburring. Generally the process consists of a cyclic alternating movement of an abrasive medium over the contour of the workpiece.As of today, process design for Abrasive Flow Machining is very time-consuming and costly as optimization of the process is usually done iteratively in experiments. The potential of a numerically supported process design was shown in previous research projects. To establish the results of the previous projects in industrial applications a knowledge transfer is necessary. The knowledge transfer will be carried out on cooperation with the partner Robert Bosch GmbH. For a better understanding of the process fundamentals and a better accordance between numerical simulations and the reality a need for fundamental research in Abrasive Flow Machining is given. In this context the main goal of this research project is to enable an optimized and accelerated process design and control in industrial Abrasive Flow Machining through numeric process models and better understanding of the process fundamentals.