Development Of Magneto Abrasive Flow Machining Process

International Journal of Machine Tools & Manufacture 42 (2002) 953–959 Development of magneto abrasive flow machining process Sehijpal Singh, H.S. Shan ∗ Department of Mechanical and Industrial Engineering, Indian Institute of Technology Roorkee, Roorkee–247 667, India Received 28 April 2001; received in revised form 25 January 2002; accepted 4 February 2002 Abstract Abrasive flow machining (AFM) is a relatively new process among non-conventional machining processes. Low material removal rate happens to be one serious limitation of almost all such processes. Limited efforts have hitherto been directed towards improving the efficiency of these processes so as to achieve higher material removal rates by applying different techniques. This paper discusses the possible improvement in surface roughness and material removal rate by applying a magnetic field around the workpiece in AFM. A set-up has been developed for a composite process termed magneto abrasive flow machining (MAFM), and the effect of key parameters on the performance of the process has been studied. Relationships are developed between the material removal rate and the percentage improvement in surface roughness of brass components when finish-machined by this process. Analysis of variance has been applied to identify significant parameters and to test the adequacy of the models. Experimental results indicate significantly improved performance of MAFM over AFM.  2002 Published by Elsevier Science Ltd. Keywords: Abrasive flow machining; Electromagnet; Response surface methodology; Magnetic abrasives 1. Introduction Abrasive flow machining (AFM) is one of the latest non-conventional machining processes, which possesses excellent capabilities for finish-machining of inaccessible regions of a component. It has been successfully employed for deburring, radiusing, and removing recast layers of precision components. High levels of surface finish and sufficiently close tolerances have been achieved for a wide range of components [1]. In AFM, a semi-solid medium consisting of a polymer-based carrier and abrasives in a typical proportion is extruded under pressure through or across the surfaces to be machined. The medium acts as a deformable grinding tool whenever it is subjected to any restriction. A special fixture is generally required to create restrictive passage or to direct the medium to the desired locations in the workpi