Process modeling and CFD simulation of two-way abrasive flow machining

The present study examines a simple, zero-order semi-mechanistic approach towards the analysis of the two-way flow abrasive flow machining process, stemming from a need to reduce the number of time-consuming and labor-intensive experimental trials. The description consists of a set of coupled models, which are the following: an inelastic non-Newtonian model to capture the flow behavior of the abrasive media; a wall slip model, as a function of wall shear-rate, to calculate the relative motion between the media and the confining wall; and a previously derived process model describing surface roughness and stock removal evolution. Predicted results were benchmarked against experimental ones obtained from studies on straight tubes with ellipsoidal cross-sections. We end this report with an application example illustrating a method to produce uniform finishing of a tube hole with complex cross-section geometry.