Robotic-Assisted LM-AF Post-Processing for Surface Roughness Improvement in Complex 3D Flow Channel Corners

Additive manufacturing (AM) enables the fabrication of complex three-dimensional components with embedded internal flow channels, but the as-built inner surfaces often exhibit high roughness and poor surface-quality uniformity, particularly at non-coplanar corner regions such as sharp bends and junctions. Conventional abrasive flow machining (AFM) can improve the overall surface finish of such channels; however, corner regions commonly remain weak-removal zones because of local flow stagnation and insufficient abrasive action. To address this limitation, this study proposes a six-degree-of-freedom (6-DOF) robotic-arm-assisted liquid metal-driven abrasive flow (LM-AF) polishing strategy in which robotic pose regulation is used to guide the liquid metal droplet to designated corner regions while preserving its responsiveness to the electric field. Numerical simulations and conventional AFM experiments on S-shaped and M-shaped spatial channels were first conducted to identify the corner regions as the primary sources of polishing non-uniformity. A robotic posture-control framework was then established through manipulator kinematics, point-cloud-based flow-direction identification, and Rodrigues-matrix-based pose transformation. On this basis, localized secondary polishing was experimentally performed on an S-shaped channel using an AC electric-field-driven liquid-metal abrasive system. The results show that corner-region roughness was significantly reduced and approached the straight-channel benchmark after secondary polishing, demonstrating a marked improvement in inner-surface uniformity. This study provides a practical route for targeted compensation polishing in complex three-dimensional internal channels and offers a new framework for robotic-assisted post-processing of AM-fabricated flow paths.