Abrasive Flow Machining Of Asymmetric Spur Gear Forging Die

Abrasive Flow Machining (AFM) is utilized for surface finishing of the precision parts. In the present study, AFM process is applied to finishing of an asymmetric spur gear forging die. The die made of AISI H13 was hardened and tempered as a stock and the asymmetric gear profile was cut by wire electrical discharge machine (WEDM). The surface quality of the die was determined with respect to the number of AFM cycles. The results show that the white layer formed during WEDM is successfully removed by using AFM for asymmetric spur gear forging die. The globules of the white layer were removed in the first AFM cycle and the average thickness of the white layer was reduced. The layer was totally eliminated after four cycles. The surface roughness value decreased with increasing in number of cycles. The surface improvement is better in the first AFM cycle and gradually saturated to a certain level. The final surface roughness along facewidth is better than involute profile direction because the flow of abrasive media is parallel to the facewidth direction