Abrasive Flow Honing Machine
Advanced Internal Finishing with Extrude Honing
Brochure Download
The Bel Air FM-AFH is a precision-engineered AFM machine, designed to deburr, polish, and refine complex internal geometries with repeatable, automated performance. This system uses a putty-like compound to achieve superior surface finishing for aerospace, medical, automotive, and industrial applications.
Not sure which equipment or media is right for your application? Send us your part for a free sample evaluation, and we’ll provide a detailed metrology report!
Applications:
The Abrasive Flow Machine is ideal for:
- Deburring internal features and passages in complex parts.
- Edge radiusing for improved fatigue resistance and durability.
- Surface improvement & polishing to achieve mirror-like finishes.
- Thermal recast layer removal for aerospace and additive manufacturing components.
- Fluid path optimization to enhance gas and liquid flow efficiency in precision components.
Why Choose Abrasive Flow Machining?
Abrasive Flow Machining (AFM), also known as extrude honing or putty honing, emerged in the 1960s to overcome the limitations of manual deburring and polishing. These traditional methods often result in inconsistencies and cannot reach complex internal features. Abrasive flow deburring is one of the key advantages of AFM machining, delivering precise and repeatable burr removal for high-performance components.
- Superior consistency compared to manual finishing methods.
- Capability to process complex internal geometries beyond the reach of traditional machining.
- Optimized material flow and fatigue strength in high-performance components.
How It Works:
AFM machining utilizes a pressurized, abrasive-laden polymer compound that is extruded through a workpiece’s internal features, effectively smoothing surfaces, removing burrs, and refining edges.
This process operates in two configurations:
- Two-Way Flow: Media is alternately pushed and pulled between two vertically opposed cylinders for uniform material removal.
- One-Way Flow: Media flows through the part in a single direction, allowing easy cleaning and rapid cycle times.
| Model | Media Cylinder Diameter (in.) | Media Displacement (cu. în.) | Maximum Media Pressure (PSI) | Maximum Fixture Diameter (in.) | Fixture Height Fully Open (in.) | Dimensions (H x W x D, in.) | Approximate Weight (lbs) | Electrical | |
|---|---|---|---|---|---|---|---|---|---|
| FM‑AFH‑275 | 5.00 | 275 | 1,600 | 10 | 18.00 | 102 x 39 x 42 | 3,000 | 460V/60Hz/3 Phase | |
| FM‑AFH‑396 | 6.00 | 396 | 1,000 | 12 | 18.00 | 100 x 39 x 42 | 4,000 | 460V/60Hz/3 Phase | |
| FM‑AFH‑704 | 8.00 | 704 | 600 | – | 18.00 | 100 x 39 x 42 | 4,000 | 460V/60Hz/3 Phase | |
| FM‑AFH‑1410 | 10.00 | 1,410 | 1,100 | 18 | 30.00 | 154 x 82 x 54 | 10,000 | 460V/60Hz/3 Phase | |
| FM‑AFH‑1696 | 12.00 | 1,696 | – | 21 | – | – | – | 460V/60Hz/3 Phase | |
| FM‑AFH‑2035 | 12.00 | 2,035 | 800 | 24 | 30.00 | 154 x 82 x 54 | 10,000 | 460V/60Hz/3 Phase | |
| FM‑AFH‑4020 | 16.00 inch | 4,020 | 600 | 36 | 34.00 | 174 x 90 x 90 | 16,000 | 460V/60Hz/3 Phase | |
- Customizable Abrasive Media: Tailored formulations for specific deburring and polishing requirements.
- Versatile Fixture Design: Configurable to accommodate diverse part geometries and batch sizes.
- Two-Way & One-Way Flow Options: Adapts to various processing needs for efficiency and precision.
- Automated Process Stability: Maintains consistent flow rate, pressure, and displacement for repeatable results.
- Precision Hydraulic System: Provides precise media extrusion with adjustable pressure and flow control.
- Media Chilling System: Prevents excessive heat buildup for more consistent media viscosity and performance.
- Fixture Shuttle & Rotary Table: Enables continuous part processing for high-throughput applications.
- Fixtures
- Designed to focus abrasive velocity on critical areas for precise material removal.
- Constructed from structural nylon (low-volume applications) or steel/aluminum with polyurethane-coated inserts (high-production applications).
- Configurable to process 1 to 50+ parts simultaneously.
- Machine System
- Hydraulic cylinders provide precise control over media flow rate and pressure.
- Automated fixture clamping & sealing ensures process stability.
- Media chilling system dissipates heat for consistent results.
- Rotary table or shuttle fixture transport streamlines workflow.
- Abrasive Media
- A viscoelastic, semi-solid compound tailored to deburring, polishing, and edge honing.
- Available in multiple formulations, from firm, putty-like media for aggressive material removal to soft, grease-like compounds for ultra-fine polishing.
- Abrasive types include Silicon Carbide, Aluminum Oxide, Diamond Powder, and Boron Carbide for different finishing needs.
- PLC-Based Touchscreen Controls: Enhances automation and user control.
- Rotary Index Table: Increases processing efficiency for multi-part workflows.
- High-Pressure Media Pump: For more aggressive material removal applications.
- Custom Fixture Design Services: Engineered for specific part geometries.
- Remote Monitoring & Diagnostics: Provides real-time tracking and predictive maintenance.
- Specialized Media Packages: Formulations for deburring, polishing, and edge conditioning.
- Noise Reduction Enclosures: Improves operator safety and workplace comfort.
- Integrated Cleaning System: Automates media recovery and cleanup for streamlined maintenance.
Our machines use a putty-like abrasive compound with different materials based on Abrasive Flow Machining (AFM) relies on a viscoelastic, putty-like abrasive compound to achieve precision deburring, polishing, and surface refinement. The choice of abrasive media depends on material hardness, desired surface finish, and application requirements.
- Silicon Carbide – Best for aggressive material removal.
- Aluminum Oxide – Versatile, ideal for general deburring and polishing.
- Diamond Powder – Ultra-fine polishing for high-precision applications.
- Boron Carbide – Used for extremely hard materials, such as ceramics and carbide components.
Comparison Table: Abrasive Media for AFM
| Abrasive Media | Best For | Material Removal Rate | Common Applications |
|---|---|---|---|
| Silicon Carbide | Aggressive material removal | High | Aerospace & industrial components, removing heavy burrs |
| Aluminum Oxide | General-purpose deburring & polishing | Medium | Automotive, medical, and general manufacturing |
| Diamond Powder | Ultra-fine polishing & surface refinement | Low | High-precision optics, aerospace, medical implants |
| Boron Carbide | Harder materials (ceramics, tungsten carbide) | Medium-High | Toolmaking, ceramic processing, wear-resistant coatings |
Abrasive Flow Machining (AFM) systems use either a one-way or two-way flow method, depending on the application. Each has distinct advantages, and the choice depends on factors like part geometry, cycle time, and material removal precision.
- One-way flow pushes the abrasive media through the part in a single direction, fully expelling it after each pass.
- Two-way flow moves the media back and forth between two opposing cylinders, ensuring consistent, uniform material removal.
Comparison Table: One-Way vs. Two-Way Flow Systems
| Factor | One-Way Flow System | Two-Way Flow System |
|---|---|---|
| Media Movement | Flows in a single direction, exiting after each cycle. | Flows back and forth between two cylinders. |
| Material Removal Control | Faster processing, but less uniform. | More consistent and even material removal. |
| Cleaning & Maintenance | Easier to clean—media is fully expelled. | More difficult to clean—media remains inside system. |
| Processing Speed | Faster for high-volume or bulk processing. | Slower but ideal for precision applications. |
| Best For | Through-holes, open passages, and bulk material removal. | Intricate internal cavities, delicate features, and uniform finishing. |
Hand deburring and polishing can be inconsistent and labor-intensive, especially when working with small, intricate, or internal features. Abrasive Flow Machining (AFM) automates the process, delivering uniform, repeatable results while reducing labor costs.
AFM is particularly effective for hard-to-reach areas and complex geometries, making it the preferred method for high-precision components in aerospace, medical, and automotive industries.
Abrasive Flow Machining vs. Hand Deburring & Polishing
| Factor | Abrasive Flow Machining (AFM) | Hand Deburring & Polishing |
|---|---|---|
| Precision & Consistency | High – Automated, repeatable, and uniform across all parts | Low – Varies by operator skill, difficult to maintain consistency |
| Access to Internal Features | Excellent – Reaches complex internal geometries | Limited – Cannot reach enclosed or intricate areas |
| Material Removal Control | Precise – Adjustable pressure and media flow for controlled finishing | Inconsistent – Depends on manual pressure and tool selection |
| Labor Efficiency | Automated – Requires minimal operator intervention | Labor-Intensive – Requires skilled workers for each part |
| Processing Speed | Fast – Can process multiple parts in one cycle | Slow – Each part must be handled individually |
| Surface Finish Quality | Superior – Smooth, uniform finish with customizable media | Varies – Can leave scratches or uneven textures |
| Production Scalability | High – Ideal for batch processing & high-volume production | Low – Manual methods are not scalable for large runs |
| Risk of Human Error | Minimal – Machine-controlled for accuracy | High – Variability in technique and skill level |
| Best for Complex Parts? | Yes – Optimized for intricate & high-precision components | No – Difficult to maintain precision on complex geometries |
Abrasive Flow Machining (AFM) is a precision finishing process that works by pushing a semi-solid, abrasive-laden media through the internal passages of a workpiece under pressure. This media—similar in texture to a firm putty—flows over internal surfaces, removing burrs, smoothing rough areas, and refining edge geometry in areas that are otherwise inaccessible to traditional tools.
Key Steps in the AFM Process:
- Fixturing the Part
The workpiece is clamped in a custom fixture designed to direct media flow precisely through the features that need deburring or polishing. - Media Extrusion
The abrasive media is extruded through the part by hydraulic cylinders—either in one direction (one-way flow) or alternating directions (two-way flow). - Material Removal
As the media flows, it gently grinds away surface imperfections, smoothing and radiusing edges in a controlled and uniform way. - Cycle Completion
The process continues for a preset number of strokes or until a target volume of media has passed through the part, ensuring consistency from part to part.
Customization and Control
AFM is highly customizable to meet different finishing needs. Process parameters that can be adjusted include:
- Media viscosity (from soft to firm, depending on part material and geometry)
- Abrasive type and grit (e.g., silicon carbide, aluminum oxide, diamond powder)
- Flow rate and pressure
- Cycle time and direction (one-way or two-way flow)
This flexibility makes AFM ideal for finishing complex internal features in aerospace, medical, automotive, and 3D-printed components—where precision, consistency, and repeatability are critical.
Want to Learn More?
See how the Bel Air FM-AFH Abrasive Flow Machine automates this process to deliver burr-free, mirror-smooth internal finishes.
An Abrasive Flow Machine (AFM machine) is used for internal deburring, polishing, and edge radiusing. It pushes a putty-like abrasive media through a part’s internal features, smoothing surfaces and removing excess material. The process is also known as abrasive flow machining (AFM) or extrude honing and is used in aerospace, medical, automotive, and precision manufacturing.
Pricing Information: Starting at $70,000. Pricing varies based on configuration and custom options. Request a Quote
Related Products
Tumbling Media
Compounds and Cleaners
