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Abstract
Keywords
1. Introduction
2. Experimental set-up
3. Modelling
4. Results and discussion
5. Conclusions
References
Figures and tables
Table 1
Table 2
http://dx.doi.org/10.1016/S0890-6955(02)00021-4
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International Journal of Machine Tools and
Manufacture
Volume 42, Issue 8, June 2002, Pages 953959
Development of magneto abrasive flow machining process
Sehijpal Singh, H.S. Shan
,
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.
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 workpiece.
Extrude Hone Corporation, USA, originally developed the AFM process in 1966. Since then, a few
empirical studies [1], [2], [3], [4] and [5] have been carried out and also research work regarding process
mechanisms, modelling of surface generation and process monitoring of AFM was conducted by Williams
and Rajurkar [6] during the late 1980s. Their work [7] was mainly related to online monitoring of AFM with
acoustic emission and stochastic modelling of the process. Loveless et al. and Kozak et al. [8] and [9]
investigated the effect of previous machining process on the quality of surface produced by AFM and the
flow behaviour of the medium used in the process. Fletcher and others [10] and [11] reported studies on the
rheological properties and the effect of temperature of the medium used in AFM. Przyklenk [12] conducted
parametric studies of AFM. Research work concerning mathematical modelling, simulation of material
removal and surface generation with the help of finite element and neural networks was presented by
different researchers [13], [14] and [15]. Steif and Haan [16] suggested the presence of dispersive
stresses, which enable wear of the surface during abrasive flow processing. The dispersive stresses are
generated because of the difference between stresses acting on abrasive particles and those acting in the
surrounding medium. Jones and Hull [17] reported the modification of existing AFM by applying ultrasonic
waves in the medium for machining blind cavities. The orbital flow machining process suggested by
Gilmore [18] 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 are to make use of combined or mutually enhanced advantages
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Development of magneto abrasive ow machining process http://www.sciencedirect.com/science/article/pii/S08906...
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and to avoid or reduce some of the adverse effects the constituent processes produce when they are
individually applied. Rajurkar and Kozak [19] have described around 15 various processes under this
category.
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 ongoing 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 workpiece.
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 cirular tubes. Shinmura
and Yamaguchi [20] and more recently Kim et al. [21], Kremen et al. [22] and Khairy [23] have reported
studies on this process. The process under investigation is the combination of AFM and MAF, and is given
the name magneto abrasive flow machining (MAFM).
2. Experimental set-up
2.1. AFM set-up
An experimental set-up (Fig. 1) was designed and fabricated. 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
workpiece (4) and index the set-up through 180 when required.
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Fig. 1.
Schematic illustration of the magneto abrasive flow machining process: 1, cylinder containing medim; 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 & 12, manifold blocks; 13, electromagnet.
Two eye bolts (5) also support this purpose. The set-up 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
workpiece. 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 workpiece. 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 workpiece 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.
2.2. The fixture
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 workpiece.
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2.3. The electromagnet
The electromagnet was designed and fabricated for its location around the cylindrical workpiece. It consists
of two poles that are surrounded by coils arranged in such a manner as to provide the maximum magnetic
field near the entire internal surface of the workpiece. Table 1 gives the specifications of the electromagnet.
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