Study on the deburring of intersecting holes with abrasive flow machining

Intersecting holes deep inside a workpiece, are difficult to deburr because of poor accessibility. When holes are small and the intersecting angle (acute angle between hole axes) is less than 45 ^o , difficulty is at its extreme. In this study, abrasive flow machining is used for a hole diameter of 3mm and intersecting angles of 30o and 45 ^o . Tests were performed for AL6061 specimens, with process parameters allocated to L8(2 ⁷ ) orthogonal array. Degree of deburring is strongly dependent on intersecting angle, abrasive grit size, and total volume of flow. Successful deburring was achieved for 30 intersecting angle.