Investigating Abrasive Flow Finishing of 3D Printed Meso Scale Channel

Abstract

Three-dimensional printed parts and components have a wide range of applications, and the number of applications is growing by the day. Outer surfaces experience severe poor finishing due to the nature of 3-D printing, i.e. the addition of layers. 3-D printed parts must be finished if they are to be used as prototypes or functional parts. To finish a piece can also be difficult, especially if it contains passages that would be on the meso-scale or below it. The idea of this research is to use a non-traditional Abrasive Flow Machining (AFM) process to finish meso-scale passages in Fused Deposition Modeling (FDM) printed components. The FDM process is used to design and fabricate components with two different passage sizes. Tooling for finishing these components with One-Way and Two-Way AFM is also designed and manufactured. First, experiments are performed on a larger 3mm passage width by modifying an existing media. Following the successful passage of the media through this passage, further experiments are carried out on a smaller 1mm passage. Because the modified existing media could not be passed through a 1mm passage, a new media was formed using a bio-coagulant called Xanthan Gum, which acts as a thickening and binding agent. Further experiments on Two-Way AFM with newly synthesized media were carried out by varying the ratio of its components, which resulted in successful media flow through a 1mm passage. As a result of the research, AFM has been identified as a feasible choice for finishing 3-D printed parts with meso-scale passages up to 1mm in width. Xanthan Gum has also been discovered to be a promising media binding and thickening agent. Further research into micro-domain passages can be conducted based on the results of this study.