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<p>Abrasive flow finishing (AFF) is a vital non-traditional process for fabricating high-precision surfaces on complex geometries in advanced materials, especially in aerospace, biomedical, and additive manufacturing applications. This review critically evaluates AFF media development, synthesis, characterization, and application, addressing challenges such as low material removal rates, high costs, and limited adaptability. By analyzing the formulations of the silicone-based, rubber-based, natural polymer-based, hydrogel-based, magnetorheological, and electrolytic AFF media, this study explains their rheological properties, preparation, and performance metrics. Characterization techniques, including rheological, mechanical, thermal, and microstructural analyses, assess the efficacy of the media, while computational fluid dynamics (CFD) and molecular dynamics (MD) simulations offer insights into flow dynamics and material removal. Key findings show that silicone-based and magnetorheological media achieve ultra-fine finishes (Ra ~ 0.01–0.06 μm) with moderate removal rates (~ 1–6 mg/min), whereas rubber-based media provide good finishes (Ra ~ 0.06–0.30 μm) but require longer times (60–240 min). Natural polymer and hydrogel-based media are sustainable alternatives but face durability and consistency challenges. Hybrid approaches, such as magnetorheological AFF (MRAFF) and electrochemical AFF (ECAFF), enhance efficiency, with ECAFF reducing roughness by approximately 40–50% in 5–15 min for conductive materials. This review identifies research gaps, including multifunctional hybrid media, real-time monitoring, and sustainable formulations, and proposes future directions. This study highlights AFF’s essential role of AFF in precision manufacturing, providing a roadmap for innovations and emphasizing precision, efficiency, and sustainability in modern manufacturing.</p>

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Exploring abrasive flow finishing media: from research gaps to synthesis methods and evaluation

  • 期刊论文

  • 发表日期：

    2025年8月5日

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  • Arsalan Ahmad,
  • Yebing Tian,
  • Abdul Wahab Hashmi

摘要

Abrasive flow finishing (AFF) is a vital non-traditional process for fabricating high-precision surfaces on complex geometries in advanced materials, especially in aerospace, biomedical, and additive manufacturing applications. This review critically evaluates AFF media development, synthesis, characterization, and application, addressing challenges such as low material removal rates, high costs, and limited adaptability. By analyzing the formulations of the silicone-based, rubber-based, natural polymer-based, hydrogel-based, magnetorheological, and electrolytic AFF media, this study explains their rheological properties, preparation, and performance metrics. Characterization techniques, including rheological, mechanical, thermal, and microstructural analyses, assess the efficacy of the media, while computational fluid dynamics (CFD) and molecular dynamics (MD) simulations offer insights into flow dynamics and material removal. Key findings show that silicone-based and magnetorheological media achieve ultra-fine finishes (Ra ~ 0.01–0.06 μm) with moderate removal rates (~ 1–6 mg/min), whereas rubber-based media provide good finishes (Ra ~ 0.06–0.30 μm) but require longer times (60–240 min). Natural polymer and hydrogel-based media are sustainable alternatives but face durability and consistency challenges. Hybrid approaches, such as magnetorheological AFF (MRAFF) and electrochemical AFF (ECAFF), enhance efficiency, with ECAFF reducing roughness by approximately 40–50% in 5–15 min for conductive materials. This review identifies research gaps, including multifunctional hybrid media, real-time monitoring, and sustainable formulations, and proposes future directions. This study highlights AFF’s essential role of AFF in precision manufacturing, providing a roadmap for innovations and emphasizing precision, efficiency, and sustainability in modern manufacturing.