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UNCONVENTIONAL
MACHINING PROCESSES

Prepared by VADAPALLI PREETHAM KUMAR

Department of Mechanical Engineering
IV YEAR B. TECH I SEMESTER
Academic Year 2025-2026
 UNIT-1
INTRODUCTION AND MECHANICAL ENERGY BASED PROCESSES
An unconventional machining process (or non-traditional machining process) is a special type
of machining process in which there is no direct contact between the tool and the workpiece.
In unconventional machining, a form of energy is used to remove unwanted material from a
given workpiece.
Need of unconventional machining processes
In several industries, hard and brittle materials like tungsten carbide, high speed steels, stainless
steels, ceramics etc., find a variety of applications. For example, tungsten carbide is used for
making cutting tools while high speed steel is used for making gear cutters, drills, taps, milling
cutters etc.
If such materials are machined with the help of conventional machining processes, either the
tool undergoes extreme wear (while machining hard work piece) or the work piece material is
damaged (while machining brittle work piece). This is because, in conventional machining,
there is a direct contact between the tool and the work piece. Large cutting forces are involved
and material is removed in the form of chips. A huge amount of heat is produced in the
workpiece. This induces residual stresses, which degrades the life and quality of the work piece
material.
Hence, conventional machining produces poor quality workpiece with poor surface finish (if
the workpiece is made of hard and brittle material). To overcome all these drawbacks, we use
unconventional machining processes to machine hard and brittle materials. We also use
unconventional machining processes to machine soft materials, in order to get better
dimensional accuracy.
Difference between Conventional Machining Processes and Conventional Machining
Processes:

Traditional / Conventional Non-Traditional / Conventional Machining

Machining Processes Processes

1. Generally macroscopic chip 1. Material removal may occur with chip

formation by shear deformation. formation or even no chip formation may take
place.

2. There may be a physical tool present. 2. There may not be a physical tool present.

3. The cutting tool is harder than the 3. Cutting tool not harder than work piece
workpiece.

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Traditional / Conventional Non-Traditional / Conventional Machining
Machining Processes Processes

4. Material removal takes place due to 4. Mostly NTM processes do not necessarily use
the application of cutting forces – mechanical energy to provide material removal.
energy domain can be classified as They use different energy domains to provide
mechanical machining.

5. Conventional machining involves 5. Whereas unconventional machining does not

the direct contact of tool and require direct contact of tool and workpiece.
workpiece.

6. Lower accuracy and surface finish. 6. Higher accuracy and surface finish.

7. Suitable for every type of material 7. Not Suitable for every type of material
economically economically

8. Tool life is less due to high surface 8. Tool life is more

contact and wear.

9. Higher waste of material due to high 9. Lower waste of material due to low or no
wear. wear.

10. Noisy operations mostly cause 10. Quieter operation mostly no sound pollutions
sound pollutions. are produced.

11. Lower capital cost 11. Higher capital cost

12. Easy set-up of equipment. 12. Complex set-up equipment.

13. The skilled or un-skilled operator 13. Skilled operator required.

may be required

14. Generally, they are manual to 14. Generally, they are a fully automated
operate. process.

15. They cannot be used to produce 15. Can be used to produce prototype parts very
prototype parts very efficiently and efficiently and economically.
economically.

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Classification of unconventional machining processes:
Unconventional machining processes can be broadly classified into several types based on four
main criteria. The classification of unconventional machining processes is given below:
Based on the type of energy used:
1. Mechanical Energy based Unconventional Machining Processes:
In these processes, unwanted material in the workpiece is removed by mechanical erosion.
The mechanical erosion can be facilitated by using any medium. The four main mechanical
energy based unconventional machining processes are:
a) Abrasive Jet Machining (AJM)
b) Water Jet Machining (WJM)
c) Abrasive Water Jet Machining (AWJM)
d) Ultrasonic Machining (USM)
e) Magnetic Abrasive Finishing (MAF)
f) Abrasive Flow Finishing (AFF)

2. Electrical Energy based Unconventional Machining Processes:

Here, electric spark discharge is used to cut and machine the workpiece. In electrical
energy-based processes, no arc is produced (as in arc welding). Instead, thousands of sparks
are produced every second.
These sparks increase the temperature of the workpiece, melt the unwanted portions and
vaporise those portions. A dielectric fluid is used for cleaning the workpiece and facilitating
a smooth spark discharge.
Processes that come under this category are:
a) Electrical Discharge Machining (EDM)
b) Wire Cut Electrical Discharge Machining (WCEDM)

3. Electrochemical Energy based Unconventional Machining Processes:

In these processes, unwanted portions of the workpiece are removed by electrochemical
effect. The workpiece (in contact with an electrolyte) is machined by ion dissolution.
Processes that come under this category are:
a) Electro-chemical Machining (ECM)
b) Electro-chemical Grinding (ECG)
c) Electro-chemical Honing (ECH)
d) Electro-chemical Deburring (ECD)

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4. Chemical Energy based Unconventional Machining Processes:
Here, chemical energy is used to remove material from the workpiece. We know that metal
can be easily converted to metallic salt, if suitable reagent is used. Chemical energy-based
processes exploit this principle. Material is removed by controlled etching of the workpiece
in the presence of a reagent known as enchant.
a) Chemical Machining (CHM)

5. Thermal Energy based Unconventional Machining Processes:

Unwanted portions of a metal can be easily removed, if it is melted or vaporized. Thermo-
electrical energy based unconventional machining processes make use of this principle.
In these processes, electrical energy is converted to a huge amount of heat by some means.
This heat is applied on a small region of the workpiece. That particular region is either
melted or vaporised. By this way, material is removed.
The following are some of the important thermo-electrical energy-based unconventional
machining processes:
a) Plasma Arc Machining (PAM)
b) Laser Beam Machining (LBM)
c) Electron Beam Machining (EBM)
d) Ion Beam Machining (IBM)

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Material and Method of Machining:

PROCESS SELECTION:
Based on the following points:
a) Physical Parameters
b) Shapes to be machined
c) Process Capability or Machining Characteristics
d) Economic Considerations

a) Physical Parameters:

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 b) Shapes to be machined:

c) Process Capability or Machining Characteristics:

1. Material Removal rate
2. Tolerance Maintained
3. Surface Finish
4. Depth of surface Damage
5. Power required for machining

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 d) Process Economy:

Advantages of UCM
 High Accuracy and surface finish in process
 Less Rejected pieces
 Increase productivity
 Tool material need not be harder than work piece material.
 Easy to machine harder and brittle materials
 There are no residual stresses in the machined material

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Dis-Advantages of UCM
 More expensive process.
 Low Material Removal Rate (MRR).
 AJM, CHM, PAM and EBM are not commercially economical Process.
Applications of UCM
 UCM are used to machine hard and difficult-to-cut materials like superalloys, carbides,
heat resisting steel, etc, which are widely used in various engineering applications.
 UCM is used for machining very thin and fragile parts, complex geometrical profiles
with superior finish, accuracy and tolerance, which are mostly preferred in aerospace,
automotive, nuclear, mining and other sectors.
 UCM are used for shaping hard cutting tools having complex geometrical profiles with
much precise accuracy.
 Apart from engineering applications, UCM processes are also used for preparation of
jewels for watch and timer movements.
 Removing glue and paint from leather objects and paintings; engraving of products with
alphanumeric or bar codes, logos, symbols, graphics and other applications.
 UCM are also used in machining of cavities in forging dies, drilling deeper holes and
irregular shaped holes which cannot be obtained by conventional machining methods.

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MECHANICAL BASED MACHINING PROCESSES
Abrasive Jet Machining (AJM):
Abrasive Jet Machining (AJM), is a mechanical energy based unconventional machining
process used to remove unwanted material from a given work piece. The process makes use of
an abrasive jet with high velocity, to remove material and provide smooth surface finish to hard
metallic work pieces.

Parts & Usages:

1. Abrasive jet: It is a mixture of a gas (or air) and abrasive particles. Gas used is carbon-di-
oxide or nitrogen or compressed air. The selection of abrasive particles depends on the hardness
and Metal Removal Rate (MRR) of the workpiece. Most commonly, aluminium oxide or silicon
carbide particles are used.
2. Mixing chamber: It is used to mix the gas and abrasive particles.
3. Filter: It filters the gas before entering the compressor and mixing chamber.
4. Compressor: It pressurizes the gas.
5. Hopper: Hopper is used for feeding the abrasive powder.
6. Pressure gauges and flow regulators: They are used to control the pressure and regulate the
flow rate of abrasive jet.
7. Vibrator: It is provided below the mixing chamber. It controls the abrasive powder feed rate
in the mixing chamber.
8. Nozzle: It forces the abrasive jet over the workpiece. Nozzle is made of hard and resistant
material like tungsten carbide.

9
Working:
 Dry air or gas is filtered and compressed by passing it through the filter and compressor.
 A pressure gauge and a flow regulator are used to control the pressure and regulate the
flow rate of the compressed air.
 Compressed air is then passed into the mixing chamber.
 In the mixing chamber, abrasive powder is fed.
 A vibrator is used to control the feed of the abrasive powder.
 The abrasive powder and the compressed air are thoroughly mixed in the chamber.
 The pressure of this mixture is regulated and sent to nozzle.
 The nozzle increases the velocity of the mixture at the expense of its pressure.
 A fine abrasive jet is rendered by the nozzle.
 This jet is used to remove unwanted material from the workpiece.
Operations that can be performed using Abrasive Jet Machining (AJM):
The following are some of the operations that can be performed using Abrasive Jet Machining:
1. Drilling & Boring
3. Surface finishing
4. Cutting
5. Cleaning
6. Deburring
7. Etching
8. Trimming
9. Milling
Process parameters:
Process parameters of Abrasive Jet Machining (AJM) are factors that influence its Metal
Removal Rate (MRR). In a machining process, Metal Removal Rate (MRR) is the volume of
metal removed from a given workpiece in unit time.
Some of the important process parameters of abrasive jet machining:
1. Abrasive mass flow rate
2. Nozzle tip distance
3. Gas Pressure
4. Velocity of abrasive particles
5. Mixing ratio
6. Abrasive grain size

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1. Abrasive mass flow rate:
 Mass flow rate of the abrasive particles is a major process parameter that influences the
metal removal rate in abrasive jet machining.
 In AJM, mass flow rate of the gas (or air) in abrasive jet is inversely proportional to the
mass flow rate of the abrasive particles.
 Due to this fact, when continuously increasing the abrasive mass flow rate, Metal
Removal Rate (MRR) first increases to an optimum value (because of increase in
number of abrasive particles hitting the workpiece) and then decreases.
 However, if the mixing ratio is kept constant, Metal Removal Rate (MRR) uniformly
increases with increase in abrasive mass flow rate.
2. Nozzle tip distance:
 Nozzle Tip Distance (NTD) is the gap provided between the nozzle tip and the
workpiece.
 Up to a certain limit, Metal Removal Rate (MRR) increases with increase in nozzle tip
distance.
 After that limit, MRR remains constant to some extent and then decreases.
 In addition to metal removal rate, nozzle tip distance influences the shape and diameter
of cut. For optimal performance, a nozzle tip distance of 0.25 to 0.75 mm is provided.
3. Gas Pressure:
 Air or gas pressure has a direct impact on metal removal rate.
 In abrasive jet machining, metal removal rate is directly proportional to air or gas
pressure.
4. Velocity of abrasive particles:
 Whenever the velocity of abrasive particles is increased, the speed at which the abrasive
particles hit the workpiece is increased.
 Because of this reason, in abrasive jet machining, metal removal rate increases with
increase in velocity of abrasive particles.
5. Mixing ratio:
 Mixing ratio is a ratio that determines the quality of the air-abrasive mixture in Abrasive
Jet Machining (AJM).
 It is the ratio between the mass flow rate of abrasive particles and the mass flow rate of
air (or gas).
 When mixing ratio is increased continuously, metal removal rate first increases to some
extent and then decreases.

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6. Abrasive grain size:
 Size of the abrasive particle determines the speed at which metal is removed.
 If smooth and fine surface finish is to be obtained, abrasive particle with small grain
size is used.
 If metal has to be removed rapidly, abrasive particle with large grain size is used.
Advantages of Abrasive Jet Machining:
 Surface of the workpiece is cleaned automatically.
 Smooth surface finish can be obtained.
 Equipment cost is low.
 Hard materials and materials of high strength can be easily machined.
 It is free from Vibrations.
Disadvantages of Abrasive Jet Machining:
 Metal removal rate is low
 In certain circumstances, abrasive particles might settle over the workpiece.
 Nozzle life is less. Nozzle should be maintained periodically.
 Abrasive Jet Machining cannot be used to machine soft materials.
Applications of Abrasive Jet Machining:
 It is used in drilling and cutting of hardened metals.
 It is used for machining brittle and heat sensitive material like glass, quartz, sapphire,
mica, ceramic etc.
 It is Use to manufacture electronic devices.
 It is used in deburring small holes and some critical zones in machine parts.

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Water Jet Machining (WJM):
 Water Jet Machining (WJM) is a mechanical energy based non-traditional machining
process used to cut and machine soft and non-metallic materials.
 It involves the use of high velocity water jet to smoothly cut a soft workpiece.
 In water jet machining, high velocity water jet is allowed to strike a given workpiece.
 During this process, its kinetic energy is converted to pressure energy.
 This induces a stress on the workpiece. When this induced stress is high enough,
unwanted particles of the workpiece are automatically removed.
Components of Water Jet Machining:
 Reservoir: It is used for storing water that is to be used in the machining operation.
 Pump: It pumps the water from the reservoir with a pressure of 117 bars.
 Intensifier: It is connected to the pump. It pressurizes the water acquired from the pump
to a desired level. It assembles with the plunger on each side of the piston, where one
end is used for inlet stores and the other end generates high pressure outlet.
 Accumulator: It is used for temporarily storing the pressurized water. It is connected to
the flow regulator through a control valve and eliminates the pressure fluctuations.
 Control Valve: It controls the direction and pressure of pressurized water that is to be
supplied to the nozzle.
 Flow regulator: It is used to regulate the flow of water.
 Nozzle: It renders the pressurized water as a water jet at high velocity. The operations
can be done about 200hours. To increase the life of the nozzle more filter need to be
added for removing undesired solids of size greater than 0.45 Microns.
 Drain and Catcher System: Post-machining, the drain and catcher system effectively
separates debris and machined particles from the water. It removes unwanted metal
particles and other contaminants, ensuring clean water returns to the reservoir for reuse
in subsequent operations.

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Working of Water Jet Machining (WJM):
 Water from the reservoir is pumped to the intensifier using a hydraulic pump.
 The intensifier increases the pressure of the water to the required level. Usually, the
water is pressurized to 200 to 400 MPa, with a velocity of 540 – 1400 m/sec.
 Pressurized water is then sent to the accumulator. The accumulator temporarily stores
the pressurized water.
 Pressurized water then enters the nozzle by passing through the control valve and flow
regulator.
 Control valve controls the direction of water and limits the pressure of water under
permissible limits.
 Flow regulator regulates and controls the flow rate of water and the flow rate will
typically from 0.5 – 2.5 l/min.
 Pressurized water finally enters the nozzle. Here, it expands with a tremendous increase
in its kinetic energy. High velocity water jet is produced by the nozzle.
 When this water jet strikes the workpiece, stresses are induced. These stresses are used
to remove material from the workpiece.
 Here, kinetic energy of water jet will be zero after striking the work piece and convert
the kinetic energy into pressure energy.
 The water used in water jet machining may or may not be used with stabilizers.
Stabilizers are substances that improve the quality of water jet by preventing its
fragmentation.
Process Parameters:
 Jet Nozzle:
a) Standoff Distance: 2.5 – 6mm
b) Nozzle Diameter: 0.1 – 0.3mm
 Jet Fluid:
a) Pressure: 150 – 1000MPa
b) Power: 8 – 80 KW
c) Velocity: 540 – 1400 m/sec
 Work piece:
a) Material Thickness: 0.8 – 25mm
b) Brittle materials will fracture, while ductile materials will cut well.
Advantages of Water Jet Machining:
 It does not change mechanical properties of work piece. It is useful for machining heat
sensitive material.
 It is environment friendly because it does not form any dust particle and used water as
cutting fluid.
 Good surface finish, where no physical tool is required.
 It can cut both soft and hard material. For machining soft materials, water jet machining
is used and for machining hard materials, abrasive water jet machining is used.
 It is ideal process for laser reflective materials where laser beam machining cannot be
used.
 Lower cost of machining.

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Disadvantages of Water Jet Machining:
 It cannot used for machining material which degrade in presence of water.
 Low metal removal rate.
 High initial cost.
 Thick material cannot be machined easily and causes rough wave pattern on the cut
surface.
Application of Water Jet Machining:

 It is used in aerospace industries.

 Abrasive jet machining is used to cut hard metal like stainless steel, titanium, Inconel
etc.
 It is used to machining or cutting reinforced plastic cut stone which reduce dust in
environment.
 Used to machining PCB (Printed Circuit Board).

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Abrasive Water Jet Machining:
 Abrasive Water Jet Machining (AWJM) is a cutting-edge manufacturing process that
uses a high-velocity stream of water mixed with abrasive particles.
 Here there will be a precisely cutting, shaping, and machining a wide range of
materials, including metals, ceramics, and composites.
 It offers advantages such as minimal heat-affected zones and intricate, burr-free cuts,
making it ideal for applications in aerospace, automotive, and architectural industries.

Components of Abrasive Water Jet Machining are:

Reservoir: The reservoir serves as the fundamental component for storing water, ensuring a
consistent supply to all other parts of the system for proper operation.
Hydraulic Pump: In the AWJM setup, the hydraulic pump assumes a crucial role as it facilitates
the transfer of fluid from one location to another. It acts as an intermediary, drawing water from
the reservoir and conveying it to the hydraulic intensifier.
Hydraulic Intensifier: Positioned after the hydraulic pump, the hydraulic intensifier is
responsible for elevating the water's pressure to the required level for effective operation.
Accumulator: The accumulator functions as a temporary water storage unit, providing water to
the system in instances of pressure drops or when high-pressure water is needed.
Control Valves: The pressure control valve within the system plays a dual role, regulating both
water pressure and its direction. A flow regulator valve is also incorporated to control the flow
of water into the system.
Flow Regulator: As its name suggests, the flow regulator governs the water flow originating
from the control valve, directing it toward the nozzle.
Abrasive Tank: Abrasive particles are pivotal in the AWJM process, especially for cutting hard
materials. Commonly used abrasives include aluminium oxides, sand, garnet, and glass
particles, among others.

16
Mixing Chamber: In contrast to traditional water jet machining, AWJM employs a mixture
comprising 70% water and 30% abrasive particles blended in the mixing chamber.
Nozzle: The nozzle's primary role is to convert high-pressure water into kinetic energy (K.E),
which is intensified as the nozzle area decreases. This high kinetic energy of water, combined
with abrasive particles, is directed onto the workpiece's surface, rapidly achieving the desired
shape and size.
Drain System: The drain system's primary function is to collect water discharged from the work
region and return it to the reservoir through the pump and filter, ensuring a continuous water
supply for the process.
Working of Abrasive Water Jet Machining:
 In this process, Water is sourced from the reservoir and distributed throughout the
system, beginning with its journey from the reservoir to the drainage system.
 Initially, the water undergoes pressurisation in the hydraulic intensifier before being
directed to the accumulator for temporary storage.
 Control valves within the system manage water pressure and control its directional flow.
 Subsequently, abrasive particles are introduced into the mixing chamber, forming a
mixture with water in a ratio of 30% abrasive particles to 70% water.
 When these high-velocity abrasive particles impact hard workpieces, they can induce
plastic deformation and fracture in the hard materials.
 Increasing the percentage of abrasives enhances material removal but diminishes the
flow characteristics of the liquid mixture.
 Consequently, the optimal abrasive percentage typically falls within the range of 40%
to 60%.
 This technology primarily finds its application in the intricate cutting of complex shapes
in materials like granite and marble.
Process Parameters:
Abrasive Particle Size: In the Abrasive Water Jet Machining (AWJM) process, abrasive
particles are typically employed within the 100 to 150 grit range.
Abrasive Materials: Commonly used abrasive materials include Garnet (which offers 30%
greater efficiency than sand), silicon carbide, and silica.
Traverse Rate: Increasing the traverse rate results in a reduction in the depth of cut, with
typical traverse speeds ranging from 100 mm/min to 5 m/min.
Stand-off Distance: An increased stand-off distance leads to a shallower depth of cut, with the
standard maintained within the range of 1-2mm.
Depth of Cut: The depth of cut in AWJM typically falls within the range of 1 mm to 250 mm.
Advantages of Abrasive Water Jet Machining:
 Versatile, cuts a wide range of materials.
 Precise and accurate.
 Minimal heat-affected zone.

17
  No need for tool changes.
 Minimal mechanical stress on the workpiece.
 Environmentally friendly (no hazardous fumes).
 Can cut thick materials.
 No need for secondary finishing processes.
 Reduced material waste.
 Suitable for intricate shapes and designs.
Disadvantages of Abrasive Water Jet Machining:
 Higher operating costs due to abrasive material usage.
 Slower cutting speed compared to some methods.
 Produces abrasive waste that requires proper disposal.
 Limited to certain thicknesses of materials.
 May generate noise during operation.
 Abrasive wear on equipment components.
 Not ideal for highly reflective or brittle materials.
 Requires regular maintenance of abrasive supply and removal systems.
 Initial equipment costs can be relatively high.
 Applications of Abrasive Water Jet Machining.
Applications of Abrasive water jet machining:
 Cutting metals (e.g., steel, aluminium, titanium).
 Precision cutting of ceramics and glass.
 Shaping and profiling composite materials.
 Cutting stone, marble, and granite.
 Trimming and shaping aerospace components.
 Creating intricate patterns in artistic designs.
 Manufacturing intricate gaskets and seals.
 Cutting automotive parts like gears and disc brakes.
 Precision machining in the aerospace industry.
 Producing custom tiles and mosaics.

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Difference Between Abrasive and Pure Water Jet Cutting:

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Magnetic Abrasive Finishing (MAF):
 We know that, every magnet has two poles [north pole (N) and south pole (S)] and
magnetic lines of force (magnetic field) travels from north pole to south pole.
 This magnetic principle is used in the Magnetic Abrasive Finishing (MAF) process.
 This process is suitable for finishing of cylindrical workpieces (external and internal
surfaces) and for flat workpieces also.
 It is used for internal finishing of tubes, external finishing of rods, finishing of flat
surfaces, etc.
 The workpiece may be made of ferromagnetic or non -ferromagnetic materials.
Working Principle:

20
  In MAF process, granular magnetic abrasive composed of ferromagnetic material (as
iron particles) and abrasive grains like Al2O3, SiC or diamond dust are used as cutting
tools and the finishing pressure is applied by electro - magnetically generated field.
 The magnetic particles are joined to each other magnetically between magnetic poles
along the lines of magnetic force forming Flexible Magnetic Abrasive Brush (FMAB).
 When a cylindrical workpiece with rotary, vibratory and axial movement is inserted in
such a magnetic field, the finishing of surface and edges is performed by the magnetic
abrasive brush.
 If the workpiece is of non - magnetic material, the lines of magnetic field go around it
(through magnetic abrasives) and if it is of magnetic material then they pass through
the workpiece.
 The magnitude of magnetic force between the two poles is also affected by the material,
shape and size of workpiece as well as magnetic poles.
 The pressure exerted by the magnetic abrasives is decreased as the gap between the
magnetic pole and workpiece is increased.
 The magnetic abrasives have been used in the form of either a mixture (unbounded) of
abrasive and ferromagnetic particles or abrasive held in a ferromagnetic matrix
(bonded) form by sintering.
 The unbounded magnetic abrasives yield higher metal removal rates whereas bonded
magnetic abrasive give better surface finish.
Process Variables:
 The process variables of MAF process are as follows:
 Type and size of magnetic abrasives
 Mixing ratio of abrasive grains with ferromagnetic particles
 Working clearance
 Rotational speed and vibration (both amplitude and frequency)
 Material properties of workpiece
 Flux density and relative speed of magnetic abrasive to the workpiece surface.
Advantages of MAF:

 MAF process can finish ferromagnetic as well as non - ferromagnetic materials.

 The finishing tool requires neither compensation nor dressing.
 This process has capability to access hard to reach areas.
 The process is capable of modifying roughness without changing the form.
 MAF is able to attain wide range of surface characteristics by careful selection of
magnetic particles.
 The set - up of process is independent of workpiece material. It can easily finish
ceramics, stainless steel, brass, coated carbide and silicon.
 Due to flexible magnetic abrasive brush, it can finish any symmetric workpiece shape.

21
Disadvantages of MAF:
 This process is not suitable for mass production.
 It is a time-consuming process.
 The cost of process is very high.
 The process is not applicable for some ordinary finishing tasks where conventional
finishing technique can be easily applied.
Applications of MAF:

 MAF is used for finishing of internal surfaces of capillary tubes and other small gauge
needles.
 It is suitable for finishing of cutting tools, air foils, optics, turbine blades, prosthetics,
etc.
 Also suitable for internal finishing of sanitary pipes, food industry, curved pipe, medical
field (stents, catheter shafts, needles, etc.).

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Abrasive Flow Machining:
 Abrasive Flow Machining is an interior surface finish process characterized
by flowing an abrasive-laden fluid through a workpiece.
 This fluid is typically very viscous, having the consistency of putty, or dough.
 AFM smooths and finishes rough surfaces, and is specifically used to remove burrs,
polish surfaces, form radii, and even remove material.
 The nature of AFM makes it ideal for interior surfaces, slots, holes, cavities, and other
areas that may be difficult to reach with other polishing or grinding processes.
 Due to its low material removal rate, AFM is not typically used for large stock-removal
operations, although it can be.

Types of Abrasive Flow Machining:

a) One Way AFM
b) Two Way AFM
c) Three Way AFM or Orbital Way
a) One Way AFM:
 In the One-Way AFM, the abrasive medium flows in only one direction — from one
media cylinder to another.
 A viscous abrasive-laden polymer is pushed through the workpiece (typically internal
passages, holes, or dies) using a hydraulic or mechanical plunger.
 The abrasive action occurs as the medium flows over the surface, removing material
through micro-cutting and shearing.
 Only one pass (or continuous one-way flow) occurs, hence the name One-Way AFM.

23
Advantages of One Way AFM:
 High surface finish quality.
 Control over temperature is not required.
 Simple tooling and part changer over.
 Can reach complex internal passages.
 Controlled and uniform material removal.
Applications of One Way AFM:
 Polishing of fuel injector nozzles.
 Deburring of cross-drilled holes.
 Finishing of Die and Mold Cavities.
 Smoothing of aerospace components.

b) Two Way AFM:

 Two-Way AFM is the most common type of Abrasive Flow Machining where an
abrasive-laden semi-solid medium is reciprocated back and forth through the workpiece
using two hydraulic rams or plungers.
 The viscous abrasive medium is placed between two opposing cylinders.
 A hydraulic ram alternately pushes the medium from the top and bottom.
 The abrasive particles in the medium polish or deburr the internal surfaces of the
workpiece.
 Material is removed uniformly from the workpiece as the medium flows back and forth.

Advantages of Two Way AFM:

 Uniform surface finish.
 Suited for complex internal geometries.
 Reduces manual polishing time.

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Applications of Two Way AFM:
 Dies and Molds (extrusion, injection).
 Fuel injector nozzles.
 Valve bodies in automotive and aerospace.
 Micro-burr removal from complex geometries.
c) Three Way AFM or Orbital AFM:
 The Three-Way Abrasive Flow Machining, also called Orbital AFM, is an advanced
version of the conventional two-way AFM process.
 It introduces a third axis of motion usually rotational or orbital movement to enhance
the abrasive action, especially for complex internal geometries and asymmetrical parts.
 Two opposing hydraulic rams push the abrasive-laden polymer medium back and forth
(just like in two-way AFM).
 Simultaneously, the workpiece is rotated or vibrated (orbital motion), adding a third
directional force.
 This multi-directional flow and motion improves the uniformity and efficiency of
material removal, especially in non-linear or asymmetrical holes.

Advantages of Three Way AFM:

 Improved uniformity in surface finish.

 Handles non-linear or asymmetric internal features.
 Reduces dead zones where media flow is low.
 Enhances precision and repeatability.
Applications of Three Way AFM:
 High-precision aerospace components.
 Medical implants with complex channels.
 Asymmetrical and 3D-printed parts.
 Intricate internal geometries.

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