Optimization of Abrasive Flow Machining Process Using Taguchi-Based PCA Method

Abstract

Abrasive Flow Machining (AFM) is a non-conventional interior surface finishing process characterized by the flow of an abrasive fluid through a workpiece. The process is particularly used for internal shapes which are difficult to process by other machining processes, because abrasion occurs only in areas where the flow is restricted. The surface finish and Material Removal Rate (MRR) have been identified as quality attributes which are directly related to productivity. This invites a multi-objective optimization problem which has been solved by Principal Component Analysis (PCA)-based Taguchi method. First, the individual response correlations have been eliminated by means of PCA. Finally, Taguchi method has been adapted to solve this optimization problem. Cylindrical workpieces of copper metal have been used for the experiments. During the experiments, parameters such as abrasive type, extrusion pressures and number of cycles were varied to explore their effects on MRR and scatter of surface roughness.

Keywords: Abrasive Flow Machining (AFM), Optimization, Material Removal Rate (MRR), Taguchi Method, Principal Component Analysis (PCA)