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3. INTRODUCTION
Magneto abrasive flow machining (MAFM) is a new technique in machining. The orbital
flow machining process has been recently claimed to be another improvement over AFM,
which performs three-dimensional machining of complex components. These processes
can be classified as hybrid machining processes (HMP)a recent concept in the
advancement of non-conventional machining. The reasons for developing a hybrid
machining process is to make use of combined or mutually enhanced advantages and to
avoid or reduce some of the adverse effects the constituent processes produce when they
are individually applied. In almost all non-conventional machining processes such as
electric discharge machining, electrochemical machining, laser beam machining, etc., low
material removal rate is considered a general problem and attempts are continuing to
develop techniques to overcome it. The present paper reports the preliminary results of an
on-going research project being conducted with the aim of exploring techniques for
improving material removal (MR) in AFM. One such technique studied uses a magnetic
field around the work piece. Magnetic fields have been successfully exploited in the past,
such as machining force in magnetic abrasive finishing (MAF), used for micro machining
and finishing of components, particularly circular tubes. The process under investigation
is the combination of AFM and MAF, and is given the name Magneto Abrasive
Flow Machining (MAFM).
3.1
Problem Definition
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4. OVERVIEW
AFM was developed in 1960s as a method to deburr, machining.
This provides
improvement in surface roughness and material removal rate, polish intricate geometries.
The process has found applications in a wide range of fields such as
aerospace, defence, and surgical and tool manufacturing industries.
Extrusion pressure, flow volume, grit size, number of cycles, media,
and work piece configuration are the principal machining parameters
that control the surface finish characteristics. Recently there has been
a trend to create hybrid processes by merging the AFF process with
other non-conventional processes. This has opened up new vistas for
finishing difficult to machine materials with
complicated shapes which would have been otherwise impossible.
These processes are emerging as major technological infrastructure for
precision, meso, micro, and nano scale engineering. This review
provides an insight into the fundamental and applied research in the
area and creates a better understanding of this finishing process, with
the objective of helping in the selection of optimum machining
parameters for the finishing of varied work pieces in practice .MAFM is a
new non-conventional machining technique .It produces surface finishes ranging from
rough to extremely fine. Here chips are formed by small cutting edges on abrasive
particles.The use of magnetic field around the work piece. It deflects the path of abrasive
flow. Here Microchipping of the surface is done.
The various limitations of Abrasive Flow Machining are overcome like:
1. Low finishing rate.
2. Low MRR.
3. Bad surface texture.
4. Uneconomical.
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5. NON-TRADITIONAL MACHINING
In present world of competition, product quality is main requirement of the customer.
It is impossible to get required degree of accuracy and quality with conventional methods
of machining. So it is required to move towards the application of non-traditional
methods.
The newer machining processes, so developed, are often called modern machining
process or unconventional machining process. These are unconventional in the sense that
the conventional tools are not employed for material removal. The energy in its direct or
indirect form is utilized. Some of the non-traditional processes are:
1.
2.
3.
4.
5.
6.
7.
These non-traditional methods cannot replace the conventional machining processes and
a particular method, found suitable under the given conditions, may not be equally
efficient under other conditions. A careful selection of the process for a given machining
conditions is therefore essential. Furthermore, the machining process has to safely
remove the material from work piece without inducing new sub-surface damages, the
machining of work piece by means of magneto abrasive flow machining (MAFM) could
be such a process. Unlike traditional grinding, lapping or honing processes with fixed
tools, MAFM applies no such rigid tool with important advantage of subjecting the work
piece to substantially lower stresses.
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6. EXPERIMENTAL SET-UP
6.1 MAFM set - up.
An experimental set-up is designed and fabricated, it is shown in fig:6.1. It consisted of
two cylinders (1) containing the medium along with oval flanges (2). The flanges
facilitate clamping of the fixture (3) that contains the work piece (4) and index the set-up
through 180 when required. Two eye bolts (5) also support this purpose. The setup is
integrated to a hydraulic press (6). The flow rate and pressure acting on piston of the
press were made adjustable. The flow rate of the medium was varied by changing the
speed of the press drive whereas the pressure acting on the medium is controlled by an
auxiliary hydraulic cylinder (7), which provides additional resistance to the medium
flowing through the work piece. The resistance provided by this cylinder is adjustable
and can be set to any desired value with the help of a modular relief valve (8). The piston
(9) of the hydraulic press then imparts pressure to the medium according to the passage
size and resistance provided by opening of the valve. As the pressure provided by the
piston of the press exceeds the resistance offered by the valve, the medium starts flowing
at constant pressure through the passage in the work piece. The upward movement of the
piston (i.e. stroke length) is controlled with the help of a limit switch. At the end of the
stroke the lower cylinder completely transfers the medium through the work piece to the
upper cylinder. The position of the two cylinders is interchanged by giving rotation to the
assembly through 180 and the next stroke is started. Two strokes make up one cycle. A
digital counter is used to count the number of cycles. Temperature indicators for medium
and hydraulic oil are also attached.
6.2 The Fixture.
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The work fixture was made of nylon, a non-magnetic material. It was specially designed
to accommodate electromagnet poles such that the maximum magnetic pull occurs near
the inner surface of the work piece.
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Figure 6.2: Schematic illustration of the magneto abrasive flow machining process
(1.Cylinder containing medium, 2. Flange, 3.Nylon fixture, 4.Workpiece, 5.Eye bolt,
6.Hydraulic press, 7.Auxiliary cylinder, 8.Modular relief valve, 9.Piston of Hydraulic
press, 10.Directional control valve, 11.Manifold blocks, 13.Electromagnet).
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7. PROCESS PARAMETERS
Following process parameters were hypothesised to influence the performance of
MAFM:
1. Flow rate (volume) of the medium,
2. Magnetic flux density,
3. Number of cycles,
4. Extrusion pressure,
5. Viscosity of the medium,
6. Grain size and concentration of the abrasive,
7. Work piece material,
8. Flow volume of the medium, and
9. Reduction ratio.
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8. PRINCIPLE
The volume of abrasive particles is carried by the abrasive fluid through the work piece.
Abrasives are impinged on the work piece with a specified pressure which is provided by
the piston and cylinder arrangement or with the help of an intensifier pump. The pressure
energy of the fluid is converted into kinetic energy of the fluid in order to get high
velocity.
When a strong magnetic field is applied around the work piece, the flowing abrasive
particles (which must essentially be magnetic in nature) experience a sideways pull that
causes a deflection in their path of movement to get them to impinge on to the work
surface with a small angle, thereby resulting in microchipping of the surface. The
magnetic field is also expected to affect the abrasive distribution pattern at the machining
surface of the work piece. The particles that otherwise would have passed without
striking the surface now change their path and take an active part in the abrasion process,
thus causing an enhancement in material removal. It is to be mentioned here that although
the mechanical pull generated by the magnetic field is small, it is sufficient to deflect the
abrasive particles, which are already moving at considerable speed. Therefore it appears
that, by virtue of the application of the magnetic field, more abrasive particles strike the
surface. Simultaneously, some of them impinge on the surface at small angles, resulting
in an increased amount of cutting wear and thereby giving rise to an overall enhancement
of material removal rate.
(a)
(b)
Figure 8.1: (a) Off-state MR fluid particles (b) Aligning in an applied magnetic field.
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9. ABRASIVE MEDIUM
The mainly used abrasive media is a Silicon based polymer, hydrocarbon gel and the
abrasive grains.The abrasive required is essentially magnetic in nature for the proper
machining process to take place. An abrasive called Brown Super Emery (trade name),
supplied by an Indian company is normally used. It contains 40% ferromagnetic
constituents, 45% Al2O3 and 15% Si2O3. SiC with silicon gel is also used as an abrasive
media.Also diamond coated magnetic abrasives can be used to finish ceramic bars.
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Figure 10.3: Orbital MAFM Process (a) Before start of finishing (b) While finishing.
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Graph 12.1: Effect of magnetic flux density and medium flow rate on MRR
Graph 12.2: Effect of number of cycles and magnetic flux density on MRR
Graph 12.3: Effect of medium flow rate and number of cycles on MRR
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Besides Singh and Shan who applied magnetic field around the work piece in A. F. Mand
observed that magnetic field significantly affect the material removal and change in
surface roughness. Ravi Sankar et.al. tried to improve the finishing rate, material removal
and surface texture by placing drill bit in the medium flow path called Drill Bit Guided
AFM. The inner part of medium slug flows along the helical flute which creates random
motion among the abrasive in inner region of the medium. This causes reshuffling of
abrasive particles at outer region. Hence, comparatively more number of new and fresh
abrasive grains interacts with the work piece surface. Also abrasive traverse path is longer
than the AFM abrasive traverse path in each cycle. It results in higher finishing rate in
DBG-AFM as compared to AFM. Material removal rate is found to decrease with
decrease in drill bit diameter.
Biing-Hwa Yanet.al., placed spiral fluted screw in the medium flowing path to improve
surface quality. He rotated different shaped tiny rods at the centre of the medium flow
path and used a low viscosity medium to finish. He concluded that the better surface
finish is achieved due to centrifugal action caused by the rod on the abrasives and this
process is called Centrifugal Force Assisted Abrasive Flow Machining (CFAAFM).
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14. ADVANTAGES
1. A very high volume of internal deburring is possible.
2. MAFM deburrs precision gears.
3. MAFM polishes internal and external features of various components.
4. MAFM removes recast layer from components.
5. Effective on all metallic materials.
6. Controllability, repeatability and cost effectiveness.
7. Less Time Consumption.
15. LIMITATIONS
16. APPLICATIONS
16.1 Automotives.
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The demand for this process is increasing among car and two wheeler manufacturers as it
is capable to make the surfaces smoother for improved air flow and better performance of
high-speed automotive engines. MAFM process is capable to finish automotive and
medical parts, and turbine engine components. Internal passages within a turbine engine
diffuser are polished to increase air flow to the combustion chamber of the engine. The
rough, power robbing cast surfaces are improved from 80-90% regardless of surface
complexities.
16.2 Dies and Moulds.
Since in the MAFM process, abrading medium conforms to the passage geometry,
complex shapes can be finished with ease. Dies are ideal workpieces for the MAFM
process as they provide the restriction for medium flow, typically eliminating fixturing
requirements. The uniformity of stock removal by MAFM permits accurate sizing of
undersized precision die passages.
The original 2 micron Rs (EDM Finish) is improved to 0.2 micron with a stock removal
of (EDM recast layer) 0.025 mm per surface.
16.3
16.4
16.5
16.6
16.7
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Figure 16.1: Surface finish improvement before and after on (a) internal passages within
turbine engine diffuser (b) medical implants (c) complete automotive engine parts.
17. CONCLUSION
A magnetic field has been applied around a component being processed by abrasive flow
machining and an enhanced rate of material removal has been achieved. Empirical
modelling with the help of response surface has led to the following conclusions about
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18. REFERENCES
1.
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2.
L.J Rhoades, Kohut T.A, Nokovich N.P, Unidirectional abrasive flow machining,
US patent number 5, 367, 833, Nov 29th,1994.
3.
Gorana V.K, Lal G.K, Forces prediction during material deformation in magneto
abrasive flow machining, Journal of manufacturing systems, Issue number 260
(2006),128-139.
4.
V.K Jain, R.K Jain, Modeling of material removal and surface roughness in magneto
abrasive flow machining process, International Journal of Machine tool &
manufacture, Issue number 39 (1999), 1903-1923.
5.
6.
Petri K.L, Bidanda B, A neural network process model for magneto abrasive flow
machining operations, Journal of manufacturing systems, Issue number 17 (1998),
52-64.
7.
Jha S, Jain V.K, Design and development of the magneto rheological abrasive flow
finishing process, International Journal of machine tool & manufacture, Issue
number 44 (2004), 1019-1029.
8.
http://www.tnmsc.cn
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