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Quality Control Technology for Abrasive Flow Precision Machining of a High-Performance Impeller.

Junye Li1, Songyuan Li1, Pingping Wei2

  • 1Ministry of Education Key Laboratory for Cross-Scale Micro and Nano Manufacturing Changchun University of Science and Technology, Changchun 130022, China.

Micromachines
|December 31, 2025
PubMed
Summary
This summary is machine-generated.

Abrasive flow machining (AFM) significantly improves surface quality for complex impellers. Optimized parameters achieved a 94% reduction in surface roughness, enhancing performance and efficiency.

Keywords:
numerical simulationsolid–liquid two-phase abrasive flowssurface quality

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Area of Science:

  • Manufacturing Engineering
  • Materials Science
  • Surface Metrology

Background:

  • High-performance impellers require precise surface finishing for optimal efficiency.
  • Complex geometries and narrow channels pose significant challenges for traditional polishing methods.
  • Existing techniques can be inefficient, damaging, or unable to achieve uniform results.

Purpose of the Study:

  • To investigate solid-liquid two-phase abrasive flow machining (AFM) for high-precision finishing of impellers.
  • To analyze the impact of flow channel structures and machining parameters on polishing effectiveness.
  • To determine optimal AFM parameters for uniform surface quality on complex impeller geometries.

Main Methods:

  • Numerical simulations were employed to analyze polishing effects under different flow channel designs and machining parameters.
  • Experimental validation utilized an orthogonal test design to identify key influencing factors.
  • Surface roughness (Ra) was measured before and after machining to quantify improvements.

Main Results:

  • A gradual flow channel structure demonstrated superior processing uniformity and intensity compared to a direct flow channel.
  • Increased inlet pressure and abrasive viscosity significantly enhanced both the strength and uniformity of the polishing effect.
  • Inlet pressure was identified as the most critical factor, followed by abrasive grain size and process cycles.

Conclusions:

  • Optimized AFM parameters (6 MPa inlet pressure, 10 cycles, 40 µm abrasive) reduced impeller surface roughness by nearly 94% (from 0.766 µm to 0.047 µm).
  • This study provides a scientifically validated approach for achieving high-quality, uniform surface finishing on complex impellers.
  • AFM offers a viable solution for enhancing the performance and efficiency of high-performance impellers through precision surface finishing.