Insights into Finishing Defects in Abrasive Flow Machining of Turbine Blade Film Cooling Holes

Abrasive flow machining (AFM) is an effective finishing process for complex internal surfaces, particularly cavities, intersecting holes, and micro-channels that are difficult to access using conventional tools. However, when low-viscosity abrasive media is used (here defined, relative to conventional putty-like viscoelastic AFM carriers (with apparent viscosities of 103–105 mPa·s), as a water-based slurry with an apparent viscosity below 300 mPa·s over the operating shear-rate range), unfavorable flow conditions during the initial polishing stage can induce local over-polishing, erosion depressions, stepped patterns, and cavitation pits, resulting in non-uniform surface quality. The relationship between these flow behaviors and polishing defects remains insufficiently understood. To address this issue, this study investigates the AFM process applied to turbine blade film cooling holes through combined experimental and numerical approaches. The observed defects include erosion depressions, stepped surface patterns, and cavitation pits. The effects of abrasive injection pressure, flow velocity, hole geometry, abrasive viscosity, and particle size on defect formation are systematically examined. The results show that the initial abrasive filling level strongly affects defect distribution by altering the evolution of shear fields and void regions within the hole. Experimentally, at high Reynolds numbers (Re > 2 × 104), intensified local shear and cavitation promote defect formation, while a moderate inclination angle (45–60°) and a higher aspect ratio (>8) are favorable for polishing uniformity. Complementary numerical simulations further indicate that smaller abrasive particles (<5 μm) and a moderate abrasive viscosity (~60 mPa·s) are predicted to improve polishing uniformity. This study clarifies the fluid-dynamic origin of polishing defects in film cooling holes and provides process guidance for suppressing local over-polishing, cavitation, and uneven material removal.