3D Additive & Extrusion Honing

Abrasive Flow Machining (AFM) & Extrusion Honing Calculator

Calculate wall shear stress ($\tau_w = \Delta P \cdot D_h / (4L)$), bi-directional extrusion cycles, material removal rates, and CAD bore stock allowances for polishing 3D printed internal passages and conformal cooling channels.

1. Input Parameters

Internal Channel Geometry / Component

Channel Hydraulic Diameter (D_h) [mm]

Passage Flow Length (L) [mm]

AFM Hydraulic Piston Pressure (P) [bar]

Extrusion pressure driving viscoelastic polymer abrasive media.

2. Calculation Results

Wall Shear Stress (tau_w)

0.0 MPa

Initial vs Target Ra

12.0 → 0.4 µm

Recommended AFM Cycles (N)

0 Cycles

Bore Stock Allowance per Wall

0.0 µm

3. Geometric Visualizer

Tooling & Vector Prepress Engineering Notes

Abrasive Flow Machining (AFM) Physics: Extruding a polyborosiloxane viscoelastic carrier loaded with silicon carbide or diamond abrasive grit through intricate internal passages polishes inaccessible additive surfaces, deburrs intersecting cross-holes, and radiuses sharp internal corners.

Vector CAD Prepress Stock Compensation: AFM removes metal uniformly from passage walls. Internal vector profiles in 3D CAD/CAM models must include negative stock allowance (undersizing bore diameters by 15–40 µm) so final dimensions hit exact nominal tolerances after extrusion honing.