magnetic abrasive flow machining

8/11/2019 Magnetic Abrasive Flow Machining

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MECHANICAL ENGINEERING DEPARTMENT

PRESENTATION

Faculty Advisor:- Made by:-

Dr. AMIT SHARMA SAMARTH SINGHAL(111670)SHASHWAT TIWARI(111672)SHIVAM MISRA(111673)SHIVANG SRIVASTAVA(111674)


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The recent increase in the use of hard, high strength andtemperature resistant materials in engineeringnecessitated the development of newer machiningtechniques.

Conventional machining or finishing methods are

not readily applicable to the materials like carbides;ceramics .Conventional machining processes when applied

to these newer materials are uneconomical, Produce poor

degree of surface finish and accuracy, Produce some

stress, highly insufficient.


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Newer machining processes may be classified on thebasis of nature of energy

employed. Abrasive flow machining (AFM) is relatively

new process among non-conventional machiningprocesses.

Low material removal rate happens to be one seriouslimitation of almost all processes. Magneto abrasive

flow machining is a new development in AFM.


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With the use of magnetic field around the work piecein abrasive flow machining, we can increase thematerial removal rate as well as the surface finish. A setup has been developed for a composite process termed

Magneto abrasive flow machining (MAFM).


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Magneto Abrasive flow machining (MAFM) is one ofthe 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,removing recast layers of precision components.

High levels of surface finish and sufficiently close

tolerances have been achieved for a wide range ofcomponents .


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.In MAFM, a semi-solid medium consisting of apolymer-based carrier and abrasives in a typicalproportion is extruded under pressure through oracross the surfaces to be machined.

The medium acts as a deformable grinding toolwhenever it is subjected to any restriction. A specialfixture is generally required to create restrictivepassage or to direct the medium to the desiredlocations in the work piece.


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Several theories have been put forward to explain themechanism of abrasion by abrasive particles . In abrasiveflow finishing (AFF), the required energy to the abrasiveparticles is provided by high pressure acting on the

viscoelastic carrier medium . The momentum that abrasiveparticle acquire due to these conditions can be consideredto be responsible for microploughing and microcutting. Inthe set-up of MAFF process, two magnetic poles S and Nare present around the workpiece. When the power isapplied to the poles, magnetic field generates the necessaryfinishing pressure between the poles. This gradient of the

magnetic field produces the attraction force between theabrasives. The magnetic abrasive particles are joined toeach other magnetically between the magnetic poles S andN along the lines of magnetic force, forming a flexiblemagnetic abrasive brush.


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Due to strong magnetic field applied around theworkpiece, the flowing abrasive particles which aremagnetic in nature experiences a sideways pull that causesa deflection in their path of movement to get them toimpinge on to the work surface with a small angel. Initially

no material removal takes place. However, the surfaceatoms become more vulnerable to removal by subsequentabrasive grains. More abrasive particles attack the surfacerepeatedly, which causes the detachment of material oftenreferred to as cutting wear. The magnetic field also affects

abrasive distribution pattern at the machining surface ofthe workpiece. The particle that otherwise would havepassed without striking the surface changes their path andtake active part in abrasion process and thus causesenhancement in the material removal.


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Following process parameters influence theperformance of MAFM:

Flow rate (volume) of the medium

Magnetic flux density

Number of cycles

Extrusion pressure


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Viscosity of the medium

Grain size and concentration of the abrasive

Work piece material

Flow volume of the medium

Reduction ratio


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MAFM Machines are classified into 3 categoriesnamely :

One-Way MachinesTwo-Way Machines

Orbital Machines


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3.Surface finishimproved by

a) Higher relative speed.

b) Smaller workingclearance.

4. More number of

cycles is required forhigh material removalrate.

3. Surface finishimproved by

a) Increase in fluxdensity.

b) Increase in finishingtime.

4. Less number of

cycles is required forhigh material removalrate.


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A very high volume of internal deburring is possible.

MAFM deburrs precision gears.

MAFM polishes internal and external features of

various components. MAFM removes recast layer from

components.

Effective on all metallic materials.

Controllability, repeatability and cost effectiveness.

Less Time Consumption.


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Freeform finishing Prosthetics Cutting Tools Turbine Blades

Airfoils

Internal Finishing Sanitary Pipes

Food Industry Capillary Tubes in Medical Field Stents, Cathater shafts, Needles, Biopsy Needles, etc Curved Pipes


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Abrasive materials tend to get embedded, if the workmaterial is ductile.

Require closed environment.

Require start up hole.


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V.K Jain, R.K Jain, Modeling of material removal andsurface roughness in magneto abrasive flow machiningprocess

Prof. Vijay Kumar Jain, Advanced machiningprocesses

www.wikipedia.com/MagneticAbrasiveFlowMachinig
http://www.wikipedia.com/MagneticAbrasiveFlowhttp://www.wikipedia.com/MagneticAbrasiveFlow


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magnetic abrasive flow machining

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