Flow directors and shields for abrasive flow machining of internal passages

Abstract

An insert apparatus for protecting a curved inner surface within a passageway from abrasion during an abrasive machining operation is disclosed. In various embodiments, the insert apparatus includes a shield having a shell shaped to match a curved portion of the curved inner surface of the passageway and a shaft having a first end connected to the shell and a second end connected to a member configured to maintain the shaft within the passageway and the shell positioned against the curved inner surface during the abrasive machining operation.

What is claimed is: 
     
         1 . An insert apparatus for smoothing an inner surface within a passageway during an abrasive machining operation, comprising:
 a shaft having a first end and a second end, the first end connected to a member configured to maintain the shaft within the passageway; and   an auger positioned along a length of the shaft from the first end toward the second end, the auger comprising one or more vanes extending in helical fashion along the length of the shaft,
 wherein one or more channels between the shaft and the inner surface, configured to transport an abrasive media within the passageway, are formed by the one or more helical vanes. 
   
     
     
         2 . The insert apparatus of  claim 1 , wherein the passageway is configured to receive a flow of the abrasive media during the abrasive machining operation. 
     
     
         3 . The insert apparatus of  claim 2 , wherein the member is a disc configured for positioning proximate one of an inlet and an exit of the passageway. 
     
     
         4 . The insert apparatus of  claim 3 , wherein the disc includes one or more apertures extending through the disc and configured to convey the abrasive media from a pump to the passageway. 
     
     
         5 . The insert apparatus of  claim 4 , wherein the disc and the auger are configured to rotate with respect to the passageway. 
     
     
         6 . The insert apparatus of  claim 4 , wherein the passageway is curved and wherein the shaft and the auger comprise a flexible material. 
     
     
         7 . An insert apparatus for smoothing an inner surface within a passageway, during an abrasive machining operation, comprising:
 a first restriction member configured for reciprocal motion along an axis of the passageway, the first restriction member defining a peak disposed proximate the inner surface and a trough proximate the axis; and   a rotary mechanism configured to reciprocally translate the first restriction member along the axis of the passageway
 wherein the first restriction member causes an abrasive media to be reciprocally translated along the axis and against the inner surface. 
   
     
     
         8 . The insert apparatus of  claim 7 , further comprising a second restriction member positioned proximate the first restriction member and a pocket disposed between the first restriction member and the second restriction member, the pocket configured to reciprocally translate the abrasive media along the axis and against the inner surface. 
     
     
         9 . The insert apparatus of  claim 8 , wherein the rotary mechanism includes a crankshaft and a connecting rod disposed between the crankshaft the first restriction member. 
     
     
         10 . The insert apparatus of  claim 9 , wherein the passageway is configured to receive a flow of the abrasive media during the abrasive machining operation. 
     
     
         11 . The insert apparatus of  claim 10 , wherein the peak and the inner surface are spaced by a constriction distance.