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<p>Finishing is an essential step in the manufacturing and production process, aimed at enhancing both the appearance and functionality of a product. The primary requirement for finishing arises from the need to improve the aesthetic appeal of a product, making it more attractive to consumers. Additionally, finishing helps protect the material from environmental damage such as corrosion, moisture, or wear, thereby increasing its durability and lifespan. AFM is a technique that suits such kind of tasks. Thermal additive Centrifugal Abrasive Flow Machining (TACAFM) process is a hybrid form of Centrifugal force assisted AFM which uses a thermal spark energy for the material removal. Now a day’s biomedical industry is mainly researching cast iron and, more frequently, specific iron-based alloys for use in biodegradable implants and the production of long-lasting medical equipment. For cast iron-based biomedical implants to guarantee biocompatibility, lessen wear and corrosion, and enhance mechanical performance and endurance within the human body, finishing is crucial. This is the main reason why the present study was done over the cast iron. This study investigates the finishing of cast iron using the Thermal Additive Centrifugal Abrasive Flow Machining (TACAFM) process. A hybrid optimization framework combining Response Surface Methodology (RSM), Weighted Grey Relational Analysis (GRA), and Principal Component Analysis (PCA) was employed to evaluate the impact of input parameters—current, duty cycle, electrode rotation, extrusion pressure, and abrasive concentration—on surface finish improvement (%Δ<i>R</i><sub><i>a</i></sub>), material removal (MR), and residual stress. Using a Central Composite Face-Centred Design (CCFCD), multi-objective optimization was performed to identify the ideal processing conditions. Analysis of Variance (ANOVA) revealed that electrical current is the most dominant parameter, contributing 20.72% to %Δ<i>R</i><sub><i>a</i></sub>, 83.47% to MR, and 91.98% to residual stress, while extrusion pressure exhibited an insignificant effect. XRD analysis further corroborated these findings, showing that residual stress intensity (peak strength) increased from 96&#xa0;k at 4 A to a maximum of 139&#xa0;k at 12 A. These results demonstrate that the thermal-spark mechanism of the current is the primary driver of material removal and surface transformation in the TACAFM process.</p>

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Multi-Objective Optimization of Cast Iron workpiece Finishing using Thermal Additive Centrifugal Abrasive Flow Machining

  • 期刊论文

  • 发表日期：

    2026年6月22日

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  • Anant Bharadwaj,
  • Parvesh Ali,
  • Dharamvir Mangal,
  • Ravinderjit Singh Walia,
  • Qasim Murtaza

摘要

Finishing is an essential step in the manufacturing and production process, aimed at enhancing both the appearance and functionality of a product. The primary requirement for finishing arises from the need to improve the aesthetic appeal of a product, making it more attractive to consumers. Additionally, finishing helps protect the material from environmental damage such as corrosion, moisture, or wear, thereby increasing its durability and lifespan. AFM is a technique that suits such kind of tasks. Thermal additive Centrifugal Abrasive Flow Machining (TACAFM) process is a hybrid form of Centrifugal force assisted AFM which uses a thermal spark energy for the material removal. Now a day’s biomedical industry is mainly researching cast iron and, more frequently, specific iron-based alloys for use in biodegradable implants and the production of long-lasting medical equipment. For cast iron-based biomedical implants to guarantee biocompatibility, lessen wear and corrosion, and enhance mechanical performance and endurance within the human body, finishing is crucial. This is the main reason why the present study was done over the cast iron. This study investigates the finishing of cast iron using the Thermal Additive Centrifugal Abrasive Flow Machining (TACAFM) process. A hybrid optimization framework combining Response Surface Methodology (RSM), Weighted Grey Relational Analysis (GRA), and Principal Component Analysis (PCA) was employed to evaluate the impact of input parameters—current, duty cycle, electrode rotation, extrusion pressure, and abrasive concentration—on surface finish improvement (%ΔRa), material removal (MR), and residual stress. Using a Central Composite Face-Centred Design (CCFCD), multi-objective optimization was performed to identify the ideal processing conditions. Analysis of Variance (ANOVA) revealed that electrical current is the most dominant parameter, contributing 20.72% to %ΔRa, 83.47% to MR, and 91.98% to residual stress, while extrusion pressure exhibited an insignificant effect. XRD analysis further corroborated these findings, showing that residual stress intensity (peak strength) increased from 96 k at 4 A to a maximum of 139 k at 12 A. These results demonstrate that the thermal-spark mechanism of the current is the primary driver of material removal and surface transformation in the TACAFM process.