The abrasive flow machining (AFM) technique has great potentials for machining micro and complicated structures, when the specific media with both favorable fluidity and machinability are essential. In the present study, components, structures and rheological behaviors of a typical type of media were analyzed, based on with the material removal mechanism was firstly discussed. The Carreau-Yasuda model was applied for simulating the AFM process, in which the shear viscosity and relative parameters were precisely determined by analyzing the rheological behaviors of the media. The wall slipping behavior was analyzed and defined by the Generalized Navier slipping model. It was showed that the polymer melt and plasticizer oil presented similar compositions and structures, containing linear chains with few side groups, contributing to the fluidity of the media. The intense peak value in the creep curve (3.55 Pa⁻¹) demonstrated a higher value of the viscous component than that of the elastic component, while the occurrence of saltatory regression further verified the linear structure of polymer chains. Owing to the retraction of streamlines from larger chambers into micro structures, and the combined effects of the shear stress and first normal stress difference, the polymer chains remained in stretched states, leading to uniform indentation depths and machining effects all over the machined surfaces. The flow velocity in the micro holes, which was obtained by the new simulation method, was roughly 1.5 m/s, proving that the retention time (2 × 10⁻³ s) was much shorter than the relaxation time of the media (230 s), indicating long-standing stretched states. The homogenous and a certain degree of shear stress, storage and loss moduli close to the inner hole surface further verified the favorable and uniform machining effects. This research is valuable for guiding the design of the media and abrasive flow machining procedures for micro structures, from aspects of either experiments or simulations.

当具有良好流动性和可加工性的特定介质必不可少时，磨料流加工 (AFM) 技术在加工微观和复杂结构方面具有巨大潜力。在本研究中，首先讨论了材料去除机理，分析了典型类型介质的成分、结构和流变行为。Carreau-Yasuda 模型用于模拟 AFM 过程，其中通过分析介质的流变行为来精确确定剪切粘度和相关参数。壁面滑移行为由广义 Navier 滑移模型进行分析和定义。结果表明，聚合物熔体和增塑剂油具有相似的组成和结构，含有具有很少侧基的直链，有助于媒体的流动性。蠕变曲线中的强烈峰值 (3.55 Pa^-1 ) 表明粘性成分的值高于弹性成分的值，而跃迁回归的发生进一步验证了聚合物链的线性结构。由于流线从较大的腔室收缩到微观结构，以及剪切应力和第一法向应力差的共同作用，聚合物链保持拉伸状态，导致整个加工表面的压痕深度和加工效果一致。通过新的模拟方法获得的微孔中的流速约为 1.5 m/s，证明保留时间 (2 × 10 ^-3 s) 远短于介质的弛豫时间（230 s），表明长期处于拉伸状态。靠近内孔表面的均质和一定程度的剪切应力、存储和损耗模量进一步验证了良好且均匀的加工效果。这项研究对于从实验或模拟的各个方面指导微结构的介质和磨料流加工程序的设计都很有价值。