GUJARAT TECHNOLOGICAL UNIVERSITY

Chandkheda, Ahmedabad
Affiliated

L.D college of Engineering

PROJECT REPORT

DEVELOPMENT OF SYSTEM FOR INTERNAL

POLISHING OF NON-MAGNETIC TUBES USING
FERROFLUID

B. E. IV year
Mechanical Branch
Submitted by
TEAM ID : 64759
group-

Name of Student - Enrollment no.

1. Prajapati manoj - 160280119084
2. Vank sunil - 160280119118
3. Sarvaiya akshay - 160280119099
4. Rathod arvind - 160280119094

Prof. V.D.SONARA Dr.N.M.BHATT

(Faculty guide) (Head of the dept.)
Introduction
Magnetic field assisted finishing sometime called magnetic
abrasive finishing a surface finishing technique in which a magnetic
field is used to force abrasive particles against the target surface. As
such, finishing of conventionally inaccessible surfaces (e.g., the
inside surface of a long curved pipe) is possible. Magnetic field-
assisted finishing (MAF) processes have been developed for a wide
variety of applications including the manufacturing of medical
components, fluid systems, optics, dies and molds, electronic
components, microelectromechanical systems, and mechanical
components.

Magnetic Assisted Finishing or "MAF" is essentially the

manipulation of a homogeneous mixture of magnetic particles and
abrasive particles with a magnetic field to impart a machining force
on a workpiece. Relative motion between the particle mixture and
the workpiece surface result in material removal. Since MAF does
not require direct contact with the tool, the particles can be
introduced into areas which are hard to reach by conventional
techniques. Additionally careful selection of magnetic particles and
abrasive particles give rise to surface texture and roughness control
that was previously impossible especially for hard to access areas.
Project summary
Now a days some parts of machine became difficult to clean
internal surface with conventional methods .In some metal tubes
there is requirement of internal polishing, but conventional
machining processes are not capable to do polishing due to lack of
accessibility, this problem can be solved by developing a system
which can polish internal part of tube, which can be straight or
curve or any shape which are not possible to polish with
conventional polishing techniques. In this system mixture of
ferrofluid and metal and abrasive particles with the help of
electromagnet which can be easily switch on or off this type of
system will play important role in application of food industry,
curved pipes and refrigeration and air conditioning systemabrasive
particles will use which will act like a liquid magnet. The type and
size of particles will decides roughness of surface or selection of
abrasive particles according to application.in this system relative
motion will create between

Purpose/objective
We aim at building table top device in order to polish and clean
tubes using ferrofluid.
Using this device we can clean internal surface of tubes which
are difficult to clean with conventional method.
Scope
 Food processing industries
 Chemical industries
 Refrigeration and air conditioning
 Sanitary pipes
 Capillary tubes in medical field stents, catheter shaft,
needles, biopsy, etc.
 Curved pipes, T shape pipes
Literature Review

Manas Das, V. K. Jain, and P. S. Ghoshdastidar

Department of Mechanical Engineering, Indian Institute of
Technology Kanpur, Kanpur, India

This article reports the experimental findings about the

improvement in out-of-roundness (OOR) of stainless steel tubes
finished by Rotational– Magnetorheological Abrasive Flow
Finishing (R-MRAFF) process. In this process, a rotating motion is
provided to the magnetorheological polishing (MRP) medium by
means of a rotating magnetic field, and simultaneously, a
reciprocating motion is provided to the polishing medium by a
hydraulic unit. By controlling these two motions, nano level
uniform smooth mirror like finished surface has been achieved and
simultaneously OOR of internal surface of tube is reduced.
Experiments are planned according to the central composite
rotatable design of response surface methodology based on the
selected range of process parameters obtained from the
preliminary experiments. Analysis of Variance (ANOVA) is
conducted and contribution of each model term affecting OOR
improvement is calculated. It has been found that R-MRAFF process
potentially reduces roundness error of axisymmetric parts
(maximum improvement in OOR = 2.04m) improving their
reliability and wear resistance. The present study shows that, OOR
improves with an increase in the rotational speed of the magnet up
to an optimum value beyond which the improvement in OOR
reduces. From the scanning electron micrographs and atomic force
micrographs it has been found that the abrasive cutting marks in R-
MRAFF process generate cross-hatch pattern which helps in oil
retention in cylindrical workpieces to reduce function.
Project development approach and project plan

Roundness plays an important role in the efficiency of axisymmetric

parts that rotate during their use . According to American Society
of Mechanical Engineers (ASME) circularity or roundness of a
feature can be defined as when all points of the surface intersected
by any plane perpendicular to an axis are equidistant from that axis.
Roundness errors are considered as one of the important
geometrical errors of axisymmetric parts because they have
negative effects on accuracy and other aspects of a machine. Out-
of-roundness (OOR) is an important property of stainless steel
components used for critical geometric conditions such as air
bearings, and they must exhibit precise form accuracy in addition
to the fine surface roughness . In a manufacturing environment,
variations on circular features may occur due to imperfect rotation,
erratic cutting action, inadequate lubrication, tool wear, incorrect
positioning of workpiece, defective machine parts, chatter,
misalignment of chuck jaws, etc. . According to Bryan and
Vanherck, wear on one ball in the ball bearing spindle can lead to
roundness error in the turned workpiece. In addition, whirling in a
hydrodynamic bearing can cause roundness error. Off centering
and component tilt in instrumental setup, oval shaped spindle
motion, machine tool vibration, component distortion due to jaws
pressure, and lesser machine tool stiffness are some of the reasons
for Roundness error in the machined products . According to Rao
et al. 75% of the roundness errors produced on a cylindrical
grinding machine is due to the erroneous motion of the spindle,
and most of the remainder is due to vibration of the grinding wheel.
It is practically impossible to produce the geometry of engineering
products perfectly in agreement with the designed dimensions. It
is so because a part passes through many machining stages.
Consequently, there is a need to control the geometry of a part in
general and roundness of the part in particular, while going through
different stages of manufacturing. However, during final finishing
operation, OOR should be brought down to the lower value or at
least equal to the designed one. For this purpose, a new polishing
method called Rotational–Magnetorheological Abrasive Flow
Finishing (R-MRAFF) process is proposed to finish internal surfaces
of stainless steel tubes. shows the schematic diagram of R-MRAFF
experimental setup, and Fig shows the magnified view of the
various parts assembled to provide rotary motion to the magnets
in the finishing zone. In the R-MRAFF process, magnetorheological
polishing (MRP) medium is extruded through the workpiece
surface, and it is given an up-anddown motion in the direction of
the tube axis by driving two opposing pistons in the medium
cylinders with the help of a hydraulic unit. At the same time, the
polishing medium (magnetic in nature) is rotated by imparting a
rotational motion to the permanent magnets (Nd–Fe–B,
45mm∗25mm∗20mm) surrounding the workpiece fixture By
intelligently controlling these two motions, uniform smooth mirror
like finished surface in the range of nanometer (nm) has been
achieved. The additional force other than the axial force acts on the
abrasive particle due to its rotational motion provided to enhance
its capabilities to abrade surface undulations from the hard
stainless steel workpiece (hardness =378HV). The combination of
these two motions (axial and rotational) in case of R-MRAFF makes
the resultant motion a helical one as compared to only axial motion
in case of Magnetorheological Abrasive Flow Finishing (MRAFF) [8].
In case of helical motion, the total length of interaction between an
abrasive particle and the workpiece is more than in case of axial
motion alone in MRAFF. Hence, better finish is achieved in case of
RMRAFF process as compared to MRAFF process for the same
number of finishing cycles.

The MRP fluid (or polishing medium) is prepared by

homogeneously mixing 26.6 vol% of electrolytic Fe powder (purity
99.5%, 250–300 mesh size, magnetic in nature) and 13.4 vol% SiC
abrasive with the base medium (paraffin oil [48 vol%] and AP3
grease [12 vol%]) . The ASTM-35 stainless steel tube (outer
diameter = 24 mm, inner diameter = 18mm, and height = 43.5mm)
is fixed between the top medium fixture and bottom medium
fixture. The permanent magnets are held by the top magnet
fixture and bottom magnet fixture surrounding the tube
workpiece [Fig. 1(b)]. The top and bottom magnet fixtures are
having four slots at their periphery to hold the magnets at 90
apart from each other. The distance between the two opposing
pole tips is set at 26mm with 1mm clearance between the pole tip
and the workpiece nearest surface, to avoid the collision between
them. A variable frequency drive (VFD) is used to control the
rotational speed of the motor which in turn controls the rotational
speed (RPM) of the magnets. In this study, the capability of R-
MRAFF process to minimize the roundness error of internal
surface of stainless steel tube has been investigated. In the
following section, force analysis has been presented to
understand the mechanics of finishing in case of R-MRAFF
process. Some preliminary experiments are conducted to decide
the significant process parameters and their ranges. To explore
the optimum combination of process parameters for minimizing
roundness error, experiments are designed according to the
central composite rotatable design(CCRD). Parametric study of R-
MRAFF process parameters has also been carried out using
regression model. The surfaces generated on the workpiece
surface before and after finishing by R-MRAFF process are
characterized using OOR profile, atomic force, micrographs,
scanning electron, and surface roughness profile.
System requirement specification
 Equipment
1.Electomegnetic coiles
2.cyllinder piston arrangement
3.flow control valve
4.ferrofluid
5.top table

 software requirement
1.Autocad
2.solideworks
3.creo
4.solidedge
5.NX-simens
6.Ansys
Calculation
Magnetic Field Formula
Magnetic field is a region surrounding a magnetic material or within
a moving electric charge where the force of magnetism acts. In
other words, the force experienced by the field due to the magnet
is known as magnetic force and this kind of field is known as
magnetic field. Magnetic field varies from one shape to another
just like solenoid has a different magnetic field than toroid.
There are two magnetic field formulas:
The magnetic field formula for current in an infinite
straight filament is given by,
Example 1
Determine the magnetic field in a solenoid
having 20 turns and current of 5 A.
Solution:
Given:
Number of turns, n = 20,
Current I = 5 A.
Magnetic field formula in a solenoid is given by,
B = μo i n
= 1.26 × 10−6 H/m × 5 × 20
= 126 x 10-6 tesla

Example 2
A toroid of radius 5 cm has 30 turns. If a current
of 5 A is passed through it, determine the
magnetic field around it.
Solution:
Given:
No of turns, N = 30,
Radius r = 5 cm
= 0.05 m,
Current I = 5A.
Magnetic field formula in a toroid coil is given by,
B = μoiN / 2πr
= 1.26×10−6 × 5 × 30 / 2π × 0.05

= 1.504 x 10-6 tesla

Magnetic field at certain distance from coil

B= μ0*i*2*A/4*π(l^2+D^2)^1.5
=1.26*10^-
6*10*2*.002826/4*3.14(.01^2+.6^2)^1.5
=25.2*10^-3 tesla
Thank you