In recent times, the usage of polymers has experienced notable growth across diverse manufacturing sectors. Polymeric gears, integral to automation, material handling systems, toys, and household appliances, have become ubiquitous. Although additive manufacturing techniques, especially Three-Dimensional (3D) printing, offer versatile applications, they grapple with challenges, notably poor surface finishing attributed to layer accumulation. This work explores the field of abrasive flow machining (AFM) in experimental settings using FDM-printed polymeric gears. The AFM medium concoction involves coal ash powder as the foundational material, EDM oil as the carrier fluid, and the infusion of glycerin as additives. Rigorous investigations were undertaken to pinpoint the optimal viscosity of the AFM medium and refine process parameters with a central focus on enhancing surface quality. A Taguchi L9 Design of Experiment (DOE) was meticulously crafted for parameter optimization using the Minitab statistical software. The investigation established a functional relationship between the output parameter (surface roughness) and key input variables (layer thickness, abrasive percentage, abrasive mesh size, and finishing time). The maximum level of AFM media optimization was attained at 33% abrasive concentration, 220 abrasive mesh size, and 60% liquid synthesizer. Additionally, the results of the investigation showed that a media viscosity of 0.50 Pa-sec, layer thickness of 0.1, and culminating time of 45 min were the optimal values for the most % improvement in surface roughness. The initial surface roughness underwent a profound reduction from 12.30 μm to 0.30 μm, marking an exceptional improvement of 97.56%. This inquiry contributes significant insights into the refinement of AFM parameters for elevating the surface finish of FDM-printed polymeric gears, promising enhanced performance across diverse applications.

This study explores the use of Polypropylene (PP) as a cost-effective matrix in composite materials, employing marble dust (MD) as a readily available filler. PP’s affordability and suitable strength make it ideal for various applications. MD, composed of CaCO₃, alumina, and silica, enhances mechanical strength and is commonly used in construction applications like concrete. Composite specimens were fabricated using the injection molding technique, and their mechanical properties (tensile, flexural, and compressive strength) were analyzed following ASTM standards. Tribological properties were assessed through a pin-on-disc apparatus with varying MD proportions. SEM and EDS analyses visually inspected the fracture types and filler distribution in the composites.

The study on Abrasive Flow Machining (AFM) and its uses for the finish of additive manufactured parts is summarized in this chapter. The literature review targets to provide contextual information and underscore significant research relevant to the present project. Extracting from significant literature-based research, the numerous characteristics and studies are categorized into five sections. The review is based on (1) the AFM process mechanism, (2) material removal rate and surface finish research, (3) important articles that influenced the current work on CFD simulation for sustainable AFM and slurry flow, (4) work on AFM for modelling, and (5) AFM for additively manufactured (AM) parts. To recognize the practical applications of AFM in recent years, details about its use in finishing healthcare components, automotive assemblies, gears, additively manufactured parts, turbine blades, and microstructures have been presented. A parametric analysis of process variables and their implications for parameter optimization and process responses is also included in this research. AFM modelling involves theoretical, analytical, and simulation-based models for stress, energy, temperature, Material Removal (MR), and surface roughness. The literature dealing with the many uses of AFM has also been included in this chapter. The findings and scope of several AFM research directions and fields have been identified and addressed in light of this systematic review. In this study, the research regarding the different uses of AFM has also been examined.