Abstract Abrasive flow finishing (AFF) is an advanced finishing process employed for finishing macro- to micro-features of workpieces. Finishing improves the functioning of the components by reducing their surface roughness. AFF process uses a polymer-based flexible medium containing abrasive particles as a finishing tool. Medium used during the AFF process plays a vital role in deciding the final surface roughness on the workpiece surface. It is the medium properties in combination with AFF input parameters that decide the end surface roughness. Micro-features on the components are mostly machined with the help of processes involving thermal energy (electrical discharge micro-machining, laser beam micro-machining). This leads to the formation of hard recast layer on the micro-machined workpiece surface. Component size and hardness of the recast layer possesses a great challenge to the finishing processes. In the current article, an economic viscoelastic medium is developed for the finishing of micro-features and its detailed rheological study is carried out. Later, experimental study of the AFF process during the finishing of micro-slots (440 ± 10 µm width) in surgical steel is performed. Developed medium successfully finishes the micro-slots with an initial surface roughness of 3.54 µm to a final surface roughness of 0.21 µm (94.07% reduction in surface roughness).

中文翻译：

---

微槽磨料流修整过程中显影介质的流变学及其与表面粗糙度的相关性

摘要 磨料流动精加工（AFF）是一种先进的精加工工艺，用于精加工工件的宏观到微观特征。精加工通过降低表面粗糙度来改善部件的功能。AFF 工艺使用含有磨料颗粒的聚合物基柔性介质作为精加工工具。AFF 过程中使用的介质在决定工件表面的最终表面粗糙度方面起着至关重要的作用。介质属性与 AFF 输入参数相结合，决定了端面粗糙度。部件上的微观特征主要在涉及热能的工艺（放电微加工、激光束微加工）的帮助下进行加工。这导致在微加工工件表面形成硬质重铸层。重铸层的部件尺寸和硬度对精加工工艺提出了很大的挑战。在当前的文章中，开发了一种经济的粘弹性介质来修饰微观特征，并对其进行了详细的流变研究。后来，对手术钢中的微槽（440 ± 10 µm 宽度）精加工过程中的 AFF 工艺进行了实验研究。开发的介质成功地完成了微槽，初始表面粗糙度为 3.54 µm，最终表面粗糙度为 0.21 µm（表面粗糙度降低 94.07%）。对手术钢中微槽（440 ± 10 µm 宽）精加工过程中的 AFF 工艺进行了实验研究。开发的介质成功地完成了微槽，初始表面粗糙度为 3.54 µm，最终表面粗糙度为 0.21 µm（表面粗糙度降低 94.07%）。对手术钢中微槽（440 ± 10 µm 宽）精加工过程中的 AFF 工艺进行了实验研究。开发的介质成功地完成了微槽，初始表面粗糙度为 3.54 µm，最终表面粗糙度为 0.21 µm（表面粗糙度降低 94.07%）。