Key Findings & Contributions
Key Findings & Contributions
A novel polymer-based abrasive medium was developed using galactomannan polymer, glycerol solution, cross-linkers, and abrasive particles. Rheological, thermal, and morphological studies (SEM, FTIR, TGA, rheometry) confirmed its stability and suitability for AFF. The medium reduced finishing cost by 57–90% compared to commercial products while maintaining strong performance.
The research established a clear mechanism for how AFF removes defects from metal AM surfaces. Through experimental evidence, stages such as loosely fused particle removal, balling elimination, peak shearing, melt-track smoothing, and micro-pit reduction were identified and mapped across different AM materials. This mechanistic framework fills a major knowledge gap in AFF post-processing.
The developed medium delivered significant improvements in surface quality:
ADAM Copper: Up to 90% Ra reduction
SLM Maraging Steel: 93% Sa reduction, balling removed by ~75 cycles
SLM H13 Spur Gear: Sa improved from 11.45 µm → 1.26 µm
These results validate AFF as an effective and versatile finishing technique for several AM technologies and geometries.
A strong correlation was established between the abrasive medium’s viscosity, viscoelasticity, and shear-thinning behaviour and its material removal capability. The elastic component supports controlled cutting of asperities, while the viscous component governs flow and MRR. This understanding provides a scientific basis for tailoring AFF media for specific AM parts.
Using RSM and ANOVA, the thesis quantified the influence of finishing parameters. The number of cycles contributed ~59.51%, making it the most dominant factor, followed by extrusion pressure and abrasive size. Predictive regression models were developed to estimate roughness outcomes and optimize finishing conditions for different materials