International Journal of Research (IJR)

c e-ISSN: 2348-6848, p- ISSN: 2348-795X Volume 3, Issue 01, January 2016

Available at http://internationaljournalofresearch.org

Experimental study of process parameters for magnetic

assisted AFM incorporating the drill bit helical flow effect
Sachin Dhull1 ; Harwinder 2 & R. S. Walia2
1,2
Research Scholar, 3Associate Professor, Delhi Technological University
Abstract
Conventional machining or finishing methods are not readily applicable to the materials like carbides,
ceramics. Low material removal rate happens to be it’s one serious limitation. Magneto abrasive flow
machining is a hybrid machining process comprising of abrasive flow machining (AFM) & Magnetic
Abrasive Finishing (MAF) .With the use of magnetic field around the work piece in abrasive flow
machining, we can increase the material removal rate as well as the surface finish. To further increase
the MRR drill bit can be placed in the flow medium of MAFM, and the process can be named as Drill Bit
guided magneto abrasive flow machining (DBGMAFM).
1. INTRODUCTION
Manufacturing process demands approximately 15% of the total manufacturing cost for finishing
operations. When the surface roughness value is less than one micron the cost of surface finishing
operation again increases sharply.

1.1 Types of machining processes

The machining processes are classified into three categories on the basis of achievable accuracy viz.
Conventional machining, precision machining and ultraprecision machining. Ultraprecision machining
are the processes by which the highest possible dimensional accuracy is, or has been achieved at a given
point of time. This is a relative definition which varies with time. It has been predicted that by 2000 AD,
machining accuracies in conventional processes would reach 1 µm.

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 International Journal of Research (IJR)
c e-ISSN: 2348-6848, p- ISSN: 2348-795X Volume 3, Issue 01, January 2016
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1.2 Advanced finishing processes (AFPS)

New advanced finishing processes were developed in last few decades to overcome limitations of
traditional finishing processes in terms of higher tool hardness requirement and precise control of
finishing forces during operation.

1.3 Abrasive Flow Machining (AFM)

Abrasive Flow Machining (AFM) was identified in 1960s as a method to deburr, polish, and radius
difficult to reach surfaces and edges by flowing an abrasive laden viscoplastic polymer over them. It uses
two vertically opposed cylinders, which extrude an abrasive medium back and forth through passage
formed by the workpiece and tooling. Abrasion occurs wherever the medium passes through the
restrictive passages.
1.4 Surface Formation in AFM
Fig.3 depicts scratches of the abrasive grains at different stages of the scratching process. The scratch of
the cutting edge in abrasive flow machining is characterized by a continuous scratch on the surface.
Alongside cutting processes, elastic and elasto-plastic forming processes take place on the surface. Based
on this observation it could be asserted, that due to the sum of the properties of the medium, the abrasive
grains come into action on the material as quasi bound cutting edges.

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 International Journal of Research (IJR)
c e-ISSN: 2348-6848, p- ISSN: 2348-795X Volume 3, Issue 01, January 2016
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Fig.4. Surface formation during abrasive flow machining

1.5 Magnetic Abrasive Finishing (MAF)
Magnetic abrasive finishing (MAF) presents a low cost option that facilitates surface as well as edge
finishing by a composite of ferromagnetic grains and fine abrasive particles. In MAF, a strong magnetic
field applied on conglomerate of abrasive particles bonded with iron particles, called magnetic abrasive
powder (MAP) generates the necessary pressure for material removal.

Fig.5 Rotating magnetic pole and magnetic abrasives

2. LITERATURE SURVEY Number of research papers and studies have been
2.1 Introduction conducted on Abrasive Flow Machining and
The literature review is the main part to Magneto Abrasive Flow Machining. Number of
understand what the important information needs reviews have been taken and analysed below to
are. From this, it is easy to determine the research complete the present study.
will be implemented and the related theory that 𝟏 Sunil Jha and V. K. Jain in their technical
has been used in previous related research. This paper “Nano-Finishing Techniques” various
can be done through internet, journal, thesis and conventional and non-conventional finishing
reference books in this research, information processes are discussed in detail and the various
needs are related to Abrasive Flow Machining, process parameters and their effect on the
Magneto Abrasive Flow Machining and Drill Bit response variables is studied. Traditional
Guided Abrasive Flow Machining. Finishing Processes such as grinding, lapping,
2.2 Previous research honing , and the advanced finishing processes
such as magnetic field assisted finishing processes

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 International Journal of Research (IJR)
c e-ISSN: 2348-6848, p- ISSN: 2348-795X Volume 3, Issue 01, January 2016
Available at http://internationaljournalofresearch.org

Magnetic Abrasive Finishing (MAF), Magnetic Extrusion pressure, Viscosity of the medium,
Float Polishing (MFP), Magnetorheological Grain size and concentration of the abrasive,
Finishing (MRF), and Magnetorheological Work piece material, Flow volume of the
Abrasive Flow Finishing (MRAFF). Chemo medium, and Reduction ratio on the response
Mechanical polishing are discussed in detail. variables MRR and Surface Finish are studied.
𝟐 Szulczynski, Hubert; Uhlmann, Eckarti in Graphs of Effect of Magnetic Flux Density and
their study on “material removal mechanisms in Medium Flow Rate on MMR, Effect of Number
AFM” they studied the material removal of Cycles and Magnetic Flux Density on MRR,
mechanism in the AFM and the effect of the grain Effect of Medium Flow Rate and Number of
size on the surface formation is studied. Surface Cycles on MRR are drawn.
formation during scratching with the abrasive 𝟓 Singh and Walia (20120 in their research
medium with the specification D100-20S(200)- paper titled “Study the Effects of Centrifugal
NX(3) at these settings was described. The images Force on Abrasive Flow Machining Process” In
were shown the depicting th surface machined this paper they discussed centrifugal force as a
with an additive for deburring. In single acting, technique for productivity enhancement in terms
the grains generate very thin scratches. During of surface roughness (Ra). A rotating Centrifugal
multiple scratching too, mainly thin scratches Force Generating (CFG) rod was used inside the
were generated on the surface of the work piece. cylindrical work piece, which provides the
𝟑 Berhanu Girma, Suhas S. Joshi, and M. V. centrifugal force to the abrasive particles normal
G. S. Raghuram in their research paper “An to the axis of workpiece. The effect of the key
Experimental analysis of Magnetic Abrasive parameters on the performance of process was
Finishing on plane surfaces” the effect of various studied. The result showed that the process
parameters such as Grain Size of MAP, Size- parameter number of cycles has the highest
Ratio, Feed Rate, Current on the response contribution towards the response characteristic
variables MRR and Surface Roughness is studied and is 54% for the percentage improvement in
and the optimum level of these parameters is ∆Ra. As the number of cycles increases from 2 to
suggested for the maximum MRR and best 6, the percentage improvement in ∆Ra is
surface finish. Graphical relationship between the maximum at the second level of 4. Lesser number
independent variable and the response variables of cycles led to better surface finish.
for MAF is also shown .In this research paper the 𝟔 Jose Cherian, Dr Jeoju M Issac in their
study was done for the plane surface an extension research paper titled “Effect of Process Variables
of the work which was done earlier for cylindrical in Abrasive Flow Machining” the effect of various
surfaces. Various differences between the two are independent variables on the response variables
also highlighted. MRR and Surface Roughness in AFM is studied.
𝟒 Kamble et. al. in their research paper titled The results highlighted that the average percent
“Use of Magneto Abrasive Flow Machining to reduction in surface roughness can be increased
improve MRR and Surface finish” the hybrid by keeping the extrusion pressure, grain mesh
machining process formed by combination of two number and Abrasive concentration at high levels,
non –conventional machining processes AFM and while the average force ratio can be increased by
MAF is proposed and it is shown that the MRR keeping extrusion pressure and abrasive
and the Surface Finish are both improved as concentration at high level and grain mesh
compared to individual processes. Problems of number at low level.
Low finishing rate, Low MRR, Bad surface Also from experiments it was clear that when the
texture, Uneconomical are removed to a certain force ratio is maximum the percentage reduction
extent.the effect of the process variables such as in surface roughness is also maximum. The
Magnetic flux density, Number of cycles, correlation coefficient between average percent

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 International Journal of Research (IJR)
c e-ISSN: 2348-6848, p- ISSN: 2348-795X Volume 3, Issue 01, January 2016
Available at http://internationaljournalofresearch.org

reduction in surface roughness and average force maximum magnetic pull occurs near the inner
ratio is higher as compared to correlations of surface of the work piece.
average percentage reduction in surface
roughness with average axial and radial forces.
3. DEVELOPED EXPERIMENTAL SETUP
In our setup we have placed a drill bit inside the
workpiece while the abrasive fluid is passed
through the workpiece while the machining cycle.
The images for which has been displayed below:-

Fig. 7 permanent magnets

3.3 Magnetic Setup
For creating magnetic pull at the inner surface of
the workpiece permanent magnets of cylindrical
shape hacing dimensions of 10x10 are used. The
magnetic strength of one single piece is 400 gauss
(approx.)

Fig. 6 set up

3.1 Machining setup

Fig.8 magnetic fixture
The machining stup is an assembled two way 3.4 Drill bit attachment for centrifugal force
AFM machine with following given For creating centrifugal force inside the
specifications. workpiece a drill bit of dia.4mm is used and is
Type of Press- 2 Pillar type fabricated Design of modified to erect it accurately inside the
capacity- 25 + 25 Ton and stroke length 96 mm workpiece.

Hydraulic cylinder Bore dia – 2 No.130mm

Hydraulic cylinder Stroke- 90 mm
Working Pressure-210 kg/𝐶𝑚2
Maximum Pressure in the Cylinder – 35 MPa
Stroke Length of Piston - 300mm

3.2 Fixture Design

The work fixture was made of poly propylene , a
non-magnetic material. It is specially designed to Fig.9 Drill bit attachment
accommodate magnet poles such that the

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 International Journal of Research (IJR)
c e-ISSN: 2348-6848, p- ISSN: 2348-795X Volume 3, Issue 01, January 2016
Available at http://internationaljournalofresearch.org

3.5 Polymer Preparation 3.7 Preparation of media

For preparation of polymer a vessel was taken We took 300 gram of polymer and 80 gram of gel
and then 1 litre of dimethyl silicon oil is poured and then it was mixed by hand complete. Then we
into it. 60 gram boric acid was then added. The added 200 gram of ferric oxide and 180 gm of
color changed to light yellow. Then 10 gram lewis silicon carbide into it. It was mixed until
acid(FeCl3.6H2O)is added into it. It changed to homogeneous solution is obtained. The media was
yellow color. Stirring is done till all the particles hence prepared.
are properly mixed. After that it was heated in a
vessel and stirring is done continuously. When
when the mixtures starts boiling and becomes
viscous,10 gram NH4CO3 is added into it and
stirring is done continuously till it becomes very
viscous and non sticky type. Then it is allowed to
cool .The polymer is hence prepared.
3.6 Preparation of gel
For making gel a vessel is taken and then half kg
of hydrocarbon (toluene)oil is added into it. Then
it is mixed with 30 gram aluminium stearate .It
turned into white color. Proper stirring is done till
the particles are properly dissolved. Then heating
is done for 20 to 25 minute and stirring is done Fig. 10 (1) Hydrocarbon Gel (2) Abrasive
continuously till it became a thick gel .It was
allowed to cool. Hence the gel is prepared. Media (3) Polymer
4. Experimental Design and Analysis
4.1 Experimental Design
The experiments were designed to study the effect of some of the DBGMAFM parameters on response
characteristics of DBGMAFM process. Taguchi parametric design methodology was adopted. The
experiments were conducted using appropriate orthogonal array (OA). An L9 (a standard 3-level OA)
having 8= (9-1) degree of freedom was selected for the present analysis. The selected number of process
parameters and their levels are given in the table:

Table 1. Process Parameters and their values at different levels

Process Parameters Unit Level 1 Level 2 Level 3

Pressure Bar 10 20 30

No. of Cycles Number 2 4 6

Magnetic field Intensity Low medium High

intensity

Design of experiments (DOE) or experimental design is the design of any information-gathering

exercises where variation is present, whether under the full control of the experimenter or not. However,
in statistics, these terms are usually used for controlled. A properly planned and executed experiment is
of the utmost importance for deriving clear and accurate conclusions from the experimental observations.

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 International Journal of Research (IJR)
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Table 2. Experimental Readings For Taguchi’s Analysis

Reading Workpiece Initial Final MRR Initial Final %Improvement

No. No. Wt. Wt. (gms) Roughness(µm) Roughness(µm)
(gms) (gms)
1 (111) 03 4.1330 4.1270 0.0086 1.96 1.34 31.63
2 (122) 10 3.7544 3.7517 0.0027 1.84 1.84 00.00
3 (133) 02 3.9416 3.94004 0.0016 1.24 1.20 03.20
4 (212) 17 4.0536 4.0511 0.0025 2.06 1.78 13.60
5 (223) 05 3.8632 3.8613 0.0019 1.58 1.36 13.92
6 (231) 07 4.1568 4.1495 0.0073 1.72 1.34 28.35
7 (313) 04 3.8311 3.8287 0.0024 1.60 1.32 17.50
8 (321) 15 4.1314 4.1295 0.0019 1.76 1.28 27.27
9 (332) 12 3.9176 3.9151 0.0025 1.92 1.64 14.58

4.2 Taguchi Analysis: Material Removal versus Pressure, Number of Cycle, Magnetic Field
Strength

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 International Journal of Research (IJR)
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Table 3.Response Table for Signal to Noise Ratios

LEVEL PRESSURE NO. OF CYCLES MAGNETIC FIELD

INTENSITY
1. -48.24 -49.87 -46.16
2. -51.03 -53.41 -53.11
3. -52.95 -48.94 -52.95
DELTA 4.71 4.47 6.95
RANK 2 3 1

Table 4. Response Table for Means

LEVEL PRESSURE NO. OF CYCLES MAGNETIC FIELD

INTENSITY
1. 0.004600 0.004200 0.005933
2. 0.003600 0.002167 0.002267
3. 0.002267 0.004100 0.002267
DELTA 0.002333 0.004100 0.003667
RANK 2 3 1

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