Abrasive Flow Machining is a finishing process utilized in several vital industrial segments, for finish-machining of manufactured components. This work will develop, as a first phase, the qualitative and quantitative relationships between process parameters such as media viscosity, extrusion pressure, flow volume and number of cycles. This will be accomplished through experimental work and stochastic modelling, since the process is random in nature. Based on the established relationships, an off- line optimization scheme will be developed and tested. An on-line monitoring and computer based control system will be implemented to improve the performance and efficiency of the process. In the area of Abrasive Flow Machining, the United States stills holds a lead both in technology and applications. This work will assist in maintaining this lead while strengthening the technological base of the domestic industry. Through improvements in process efficiency and process capability, this work will also broaden the application base of this technique, with economic benefits to a wide spectrum of manufacturing industries.
