Open Access Open Access  Restricted Access Subscription or Fee Access

Exploring Abrasive Flow Finishing of 3D Printed Mesoscale Passage

Prabhat Kumar, Vikas Nandal, Amit Gupta


3-D printed parts and components have gained wide applicability which continues to increase day by day. However, due to the very nature of 3-D printing process, i.e. layer additions, outer surfaces are subject to poor finishing. Finishing 3-D printed parts is thus a necessity if they are to be used for prototyping or functional purpose. But, finishing remains a challenge, especially if the part contains passages that lie within and below meso-scale. As, it was not possible to pass the modified existing media through 1mm passage, a new media was synthesized using a bio-coagulant called Xanthan Gum which acts as a thickening and binding agent. Further experiments were performed on Two-Way AFM using newly synthesized media by varying the ratio of its components which resulted in successful flow of media through 1mm passage also. The performed work thus establishes AFM as a suitable process for finishing 3-D printed parts containing meso-scale passages up to 1mm width. Also, Xanthan Gum is found to be a promising agent for binding and thickening media. On the basis of this study, further explorations on micro-domain passages can also be performed.


Fused deposition modeling, abrasive flow machining, media, complex meso structure.

Full Text:



Gao, W., Zhang, Y., Ramanujan, D., Ramani, K., Chen, Y., Williams, C.B., Wang, C.C., Shin, Y.C., Zhang, S. and Zavattieri, P.D., 2015. The status, challenges, and future of additive manufacturing in engineering. Computer-Aided Design, 69, pp.65-89.

Wikipedia "Fused deposition modeling" retrieved from – – consulté le 10-02-2015.

Mali, H.S., Prajwal, B., Gupta, D. and Kishan, J., 2018. Abrasive flow finishing of FDM printed parts using a sustainable media. Rapid Prototyping Journal.

Jain, R.K., Jain, V.K. and Dixit, P.M., 1999. Modeling of material removal and surface roughness in abrasive flow machining process. International Journal of Machine Tools and Manufacture, 39(12), pp.1903-1923.

Jha, S. and Jain, V.K., 2004. Design and development of the magnetorheological abrasive flow finishing (MRAFF) process. International Journal of Machine Tools and Manufacture, 44(10), pp.1019-1029.

Cheema, M.S., Venkatesh, G., Dvivedi, A. and Sharma, A.K., 2012. Developments in abrasive flow machining: a review on experimental investigations using abrasive flow machining variants and media. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 226(12), pp.1951-1962.

Sambharia, J. and Mali, H.S., 2019. Recent developments in abrasive flow finishing process: A review of current research and future prospects. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 233(2), pp.388-399.

Bouland, C., Urlea, V., Beaubier, K., Samoilenko, M. and Brailovski, V., 2019. Abrasive flow machining of laser powder bed-fused parts: numerical modeling and experimental validation. Journal of Materials Processing Technology, 273, p.116262.

Wang, X., Fu, Y. and Gao, H., 2016. Finishing of additively manufactured metal parts by abrasive flow machining. In Proc. 27th Annu. Int. Solid Free. Fabr. Symp., Austin, TX (pp. 2470-2472).

Duval-Chaneac, M.S., Han, S., Claudin, C., Salvatore, F., Bajolet, J. and Rech, J., 2018. Experimental study on finishing of internal laser melting (SLM) surface with abrasive flow machining (AFM). Precision Engineering, 54, pp.1-6.

Nagalingam, A.P. and Yeo, S.H., 2018. Controlled hydrodynamic cavitation erosion with abrasive particles for internal surface modification of additive manufactured components. Wear, 414, pp.89-100.

Leong, K.F., Chua, C.K., Chua, G.S. and Tan, C.H., 1998. Abrasive jet deburring of jewellery models built by stereolithography apparatus (SLA). Journal of Materials Processing Technology, 83(1-3), pp.36-47.

Tan, K.L. and Yeo, S.H., 2017. Surface modification of additive manufactured components by ultrasonic cavitation abrasive finishing. Wear, 378, pp.90-95.

Kar, K.K., Ravikumar, N.L., Tailor, P.B., Ramkumar, J. and Sathiyamoorthy, D., 2009. Performance evaluation and rheological characterization of newly developed butyl rubber based media for abrasive flow machining process. Journal of materials processing technology, 209(4), pp.2212-2221.

Mali, H.S. and Manna, A., 2010. Optimum selection of abrasive flow machining conditions during fine finishing of Al/15 wt% SiC-MMC using Taguchi method. The International Journal of Advanced Manufacturing Technology, 50(9-12), pp.1013-1024.

Jain, V.K. and Adsul, S.G., 2000. Experimental investigations into abrasive flow machining (AFM). International Journal of Machine Tools and Manufacture, 40(7), pp.1003-1021.

Venkatesh, G., Sharma, A.K. and Kumar, P., 2015. Fine finishing of SiC microchannels using abrasive flow machining.

Jung, D., Wang, W.L., Knafl, A., Jacobs, T.J., Hu, S.J. and Assanis, D.N., 2008. Experimental investigation of abrasive flow machining effects on injector nozzle geometries, engine performance, and emissions in a DI diesel engine. International Journal of Automotive Technology, 9(1), pp.9-15.

Chen, F., Hao, S., Miao, X., Yin, S. and Huang, S., 2018. Numerical and experimental study on low-pressure abrasive flow polishing of rectangular microgroove. Powder technology, 327, pp.215-222.

Tzeng, H.J., Yan, B.H., Hsu, R.T. and Chow, H.M., 2007. Finishing effect of abrasive flow machining on micro slit fabricated by wire-EDM. The International Journal of Advanced Manufacturing Technology, 34(7-8), pp.649-656.

Gorana, V.K., Jain, V.K. and Lal, G.K., 2006. Forces prediction during material deformation in abrasive flow machining. Wear, 260(1-2), pp.128-139.

Walia, R.S., Shan, H.S. and Kumar, P., 2008. Determining dynamically active abrasive particles in the media used in centrifugal force assisted abrasive flow machining process. The International Journal of Advanced Manufacturing Technology, 38(11-12), pp.1157-1164.


  • There are currently no refbacks.

Copyright (c) 2021 Recent Trends in Fluid Mechanics