TOPIC NAME :MAGNETO ABRASIVE FLOW MACHINING

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SG 11911
MECH 6TH SEM

 Hybrid

machining is improve technology of

machining process which can be achieved by
combining different machining action.
Hybrid of any two machining is done only if it
have some advantages over single phase
machining.
Examples of hybrid machining are abrasive
water jet machining, water jet guided laser
machining etc

Magneto abrasive flow machining (MAFM) is a new technique in

machining. The orbital flow machining process 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 is to make use of combined or mutually
enhanced advantages and to avoid or reduce some of the adverse effects
the constituent processes produce when they are individually applied.
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 on-going 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 work piece. 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 circular tubes. The process under investigation
is the combination of AFM and MAF, and is given the name Magneto
Abrasive Flow Machining (MAFM).

The volume of abrasive particles is carried by the abrasive fluid through

the work piece. Abrasives are impinged on the work piece with a
specified pressure which is provided by the piston and cylinder
arrangement or with the help of an intensifier pump. The pressure energy
of the fluid is converted into kinetic energy of the fluid in order to get
high velocity.
When a strong magnetic field is applied around the work piece, the
flowing abrasive particles (which must essentially be magnetic in nature)
experience 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
angle, thereby resulting in microchipping of the surface. The magnetic
field is also expected to affect the abrasive distribution pattern at the
machining surface of the work piece. The particles that otherwise would
have passed without striking the surface now change their path and take
an active part in the abrasion process, thus causing an enhancement in
material removal. It is to be mentioned here that although the
mechanical pull generated by the magnetic field is small, it is sufficient
to deflect the abrasive particles, which are already moving at
considerable speed. Therefore it appears that, by virtue of the
application of the magnetic field, more abrasive particles strike the
surface. Simultaneously, some of them impinge on the surface at small
angles, resulting in an increased amount of cutting wear and thereby
giving rise to an overall enhancement of material removal rate.

. 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 work piece (4) and index the set-up
through 180 when required. Two eye bolts (5)
also support this purpose. The setup 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 work piece

CROSS SECTIONAL VIEW OF MASM

Experimental set-up
An experimental set-up for developing MAFM contained two cylinders
containing the medium along with oval flanges , mainly for clamping of
the fixture that contains the workpiece . The set-up is integrated to
a hydraulic press. The flow rate of the medium was varied by changing
the speed of the press drive and an auxiliary hydraulic cylinder allowed
pressure change. The resistance provided by this cylinder is adjustable
and can be set to any desired value with the help of a modular relief
valve . The stroke length is controlled with the help of a limit
switch. Two strokes make up one cycle.
The fixture
nylon,is used because it allows electromagnet poles such that the
maximum magnetic pull occurs near the inner surface of the workpiece.

The electromagnet
the cylindrical workpiece was surrounded by the electromagnet. two
poles that are surrounded by coils arranged are present in it.
The abrasive medium
a silicon-based polymer, hydrocarbon gel and the abrasive grains are used
as the abrasives.

PROCESS PARAMETERS
Following process parameters were hypothesised
to influence the performance of MAFM:
1.
2.
3.
4.
5.
6.
7.
8.
9.

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, and
Reduction ratio.

SET UP OF MASM

 The

various Advantages of magneto Abrasive

Flow Machining over abrasive flow machining
are :
1. high finishing rate.
2. High MRR.
3. Good surface texture.
4. wide range of applications