710231Mollart Engineering; Abrasive Flow Machining of Complex GeometryClosedGRD Proof of ConceptInnovate UKSurface finishing requirements within high value manufacturing are critical to fulfilling a products' key functional purpose. Studies have shown the cost of manual finishing can be between 9% and 30% of a precision product’s final cost (Aurich et al, 2009; Saha & Das, 2010). The abrasive flow machining (AFM) process forces putty containing abrasive grit through/around a component, in order to grind the surface in a precise mechanical manner. The putty within the abrasive media is soft and flowable, with excellent conformation to part geometry as pressure is applied through hydraulic cylinders. This flexibility allows AFM to act on part features inaccessible by hand tools and provide a carefully controlled grinding action which has the potential to replace more traditional manufacturing finishing operations. While AFM has been successful in short parts with simple geometry, the process has never been successfully implemented in long parts with complex geometry. This project aims to; 1) Gain extensive knowledge of the media-part-machine relationship; 2) Manufacture an abrasive media suitable for long cavities; 3) Apply process knowledge to replace traditional finishing operations within MOLLART; 4) Develop modular and reconfigurable tooling; 5) Establish a subcontract capability within MOLLART with a view to automation. Long, complex parts in production at Mollart can be worth up to £40,000 each, requiring a minimum of 45 hours manual deburring. Key sectors served by the AFM process will be oil & gas, medical, defence, aerospace and general engineering. Increasing the process capability of AFM will impact on MOLLART's bottom line, reducing expenditure on labour, tooling, and energy costs. Reducing the use of disposable tooling by developing modular solutions will result in lower raw material consumption and lower waste generation. AFM will remove human error and variability seen on current parts and will provide MOLLART with a robust process to offer as a cost-effect.