MECHANICAL ENGINEERING DEPARTMENT

PRESENTATION


Faculty Advisor:- Made by:-
Dr. AMIT SHARMA SAMARTH SINGHAL(111670)
SHASHWAT TIWARI(111672)
SHIVAM MISRA(111673)
SHIVANG SRIVASTAVA(111674)

The recent increase in the use of hard, high strength and
temperature resistant materials in engineering
necessitated the development of newer machining
techniques.
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.
Newer machining processes may be classified on the
basis of nature of energy
employed. Abrasive flow machining (AFM) is relatively
new process among non-conventional machining
processes.
Low material removal rate happens to be one serious
limitation of almost all processes. Magneto abrasive
flow machining is a new development in AFM.

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. A set
up has been developed for a composite process termed
Magneto abrasive flow machining (MAFM).
Magneto Abrasive flow machining (MAFM) 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,
removing recast layers of precision components.
High levels of surface finish and sufficiently close
tolerances have been achieved for a wide range of
components .

.In MAFM, 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 work piece.
Several theories have been put forward to explain the
mechanism of abrasion by abrasive particles . In abrasive
flow finishing (AFF), the required energy to the abrasive
particles is provided by high pressure acting on the
viscoelastic carrier medium . The momentum that abrasive
particle acquire due to these conditions can be considered
to be responsible for microploughing and microcutting. In
the set-up of MAFF process, two magnetic poles S and N
are present around the workpiece. When the power is
applied to the poles, magnetic field generates the necessary
finishing pressure between the poles. This gradient of the
magnetic field produces the attraction force between the
abrasives. The magnetic abrasive particles are joined to
each other magnetically between the magnetic poles S and
N along the lines of magnetic force, forming a flexible
magnetic abrasive brush.

Due to strong magnetic field applied around the
workpiece, the flowing abrasive particles which are
magnetic in nature experiences 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 angel. Initially
no material removal takes place. However, the surface
atoms become more vulnerable to removal by subsequent
abrasive grains. More abrasive particles attack the surface
repeatedly, which causes the detachment of material often
referred to as cutting wear. The magnetic field also affects
abrasive distribution pattern at the machining surface of
the workpiece. The particle that otherwise would have
passed without striking the surface changes their path and
take active part in abrasion process and thus causes
enhancement in the material removal.

Following process parameters influence the
performance of MAFM:

Flow rate (volume) of the medium

Magnetic flux density

Number of cycles

Extrusion pressure
Viscosity of the medium

Grain size and concentration of the abrasive

Work piece material

Flow volume of the medium

Reduction ratio
MAFM Machines are classified into 3 categories
namely :

One-Way Machines
Two-Way Machines
Orbital Machines

AFM
1. Surface irregularities
such as scratch,bumps,
out of roundness cannot be
corrected.
2.Machined depth
increases by
a) Increase in particle size.
b) Smaller working
clearance.
1. Surface irregularities
such as scratch, bumps,
out of roundness can be
corrected easily.

2.Machined depth
increases by
a)Increase in magnetic flux
density
b) Increase in particle size.
MAFM
3.Surface finish
improved by
a) Higher relative speed.
b) Smaller working
clearance.

4. More number of
cycles is required for
high material removal
rate.

3. Surface finish
improved by
a) Increase in flux
density.
b) Increase in finishing
time.
4. Less number of
cycles is required for
high material removal
rate.

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.
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

Abrasive materials tend to get embedded, if the work
material is ductile.
Require closed environment.
Require start up hole.
V.K Jain, R.K Jain, Modeling of material removal and
surface roughness in magneto abrasive flow machining
process

Prof. Vijay Kumar Jain, Advanced machining
processes

www.wikipedia.com/MagneticAbrasiveFlowMachinig