Open Access

Table 3

Key capabilities and noted findings of AFM processes.

Process Applications Benefits Limitations Challenges
DBG-AFF [67] Finishing of 3D internal surfaces and drilling of micro-holes in materials like AISI 1040, AISI 4340 etc. 2.35 times increase in Material removal and 1.6 times improvement in %Δ Ra was improved as compared to AFF Only internal surfaces can be finished. To finish external surface with high finishing rate.
CFAFM [68] Small holes in micro range, internal 3D Complex surfaces. Finishing time was reduced by 70–80% and roughness improvement was 35–40% as compared to basic AFM. Only internal surfaces can be finished. Control the medium properties during operation.
R-AFF [69] MMCs. and extremely hard complex surfaces Roughness value changed from 0.6 ± 0.1 μm to 0.25 ± 0.05 μm Material with sharp edges cannot be finished. Temperature rise was the major problem due to which viscosity of fluid decreases.
HLX-AFM [30] Improving
the flow characteristics of fluid carrying channels, removing
the burrs and recast layers
Material removal was 2.35 times more than basic AFM Suitable for cylindrical shaped geometrical surfaces. To finish the complex surface other than cylindrical
ECAFM [71] Ability to finish fast even if the component is thin/delicate and made
of hard alloys.
46.83% improvement in %ΔRa in minimal time. Only for conductive material and glossy surface generated after finishing due to chemical reaction on the surface 3-D CFD simulation of abrasive-laden medium
UAAFM [72] Bevel gear made up of hard material, Ferromagnetic materials The average change in roughness value was from 1.0 μm to 0.4 μm Mostly used for ferromagnetic material with a greater hardness Control over finishing forces during operation.
MRAFF [73] Biological components like knee joint and optical glasses Change in roughness value was from 0.47 μm to 0.35 μm for SS material in 200 cycles. No significant improvement with magnetic materials Reduce the finishing time of complex features

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