Experimental Investigation of Electrochemical- Magnetic Assisted Helical Abrasive Flow Machining for Surface Roughness Improvement and Material Removal

The increasing use of advanced engineering materials and components with intricate internal geometries has created a growing demand for precision finishing processes capable of achieving superior surface quality in difficult-to-access regions. Abrasive Flow Machining (AFM) is an effective non-traditional finishing technique in which a viscoelastic abrasive medium is extruded through or across the workpiece to improve surface characteristics. However, its relatively low material removal rate and prolonged finishing time limit its use in precision applications. To address these limitations, this study proposes and experimentally investigates an Electrochemical-assisted Magnetic Helical Abrasive Flow Machining (ECMHAFM) process for finishing the internal surface of a brass workpiece. The proposed hybrid process integrates electrochemical dissolution, magnetic assistance, and helical abrasive motion to intensify the interaction between the abrasive medium and the workpiece surface. A guar-gum based semi-solid abrasive medium containing aluminium oxide (Al2O3) and magnetic abrasive particles is employed, with sodium chloride (NaCl) serving as electrolyte. The abrasive medium is extruded through the machining zone under controlled pressure using a helical-profile rod, thereby promoting enhanced abrasive contact and material removal along the internal surface. The machining performance of the proposed process is evaluated in terms of material removal and percentage improvement in surface roughness. The study provides an experimental assessment of the synergistic contribution of electrochemical action, magnetic particle manipulation, and helical abrasive flow to surface finishing performance. The proposed ECMHAFM approach offers a potential route for improving the efficiency and surface-finishing capability of conventional abrasive flow machining, particularly for precision finishing of complex internal surfaces.