Magneto Abrasive Flow Machining 2019-20

Chapter 1

INTRODUCTION

1.1 Magneto abrasive flow machining

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).

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Chapter 2
HISTORY
2.1 Abrasive flow machining
Abrasive flow machining (AFM) is also known as abrasive flow deburring or extrude honing, is an
interior surface finishing process characterized by flowing an abrasive-laden fluid through a workpiece. This
fluid is typically very viscous, having the consistency of putty, or dough. AFM smooths and finishes rough
surfaces, and is specifically used to remove burrs, polish surfaces, form radii, and even remove material. The
nature of AFM makes it ideal for interior surfaces, slots, holes, cavities and other areas that may be difficult to
reach with other polishing or grinding process.

2.2 Process of Abrasive flow Machining

In abrasive flow machining, the abrasive fluid flows through the workpiece, effectively performing erosion.
Abrasive particles in the fluid contact raised features on the surface of the workpiece and remove them. The
fluid is forced through the workpiece by a hydraulic ram, where it acts as a flexible file, or slug, molding itself
precisely to the shape of the workpiece. The highest amount of material removal occurs in areas where the
flow of the fluid is restricted; according to Bernoulli's Principle, the flow speed and pressure of the fluid
increase in these areas, facilitating a higher material removal rate (MRR). The pressure exerted by the fluid on
all contacting surfaces also results in a very uniform finish. AFM may be performed once, as a one-way flow
process, or repeatedly as a two-way flow process. In the two-way flow process, a reservoir of medium exists
at either end of the workpiece, and the medium flows back and forth through the workpiece from reservoir to
reservoir.

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Chapter 3
CLASSIFICATION
3.1 Magneto abrasive flow machining
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 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. 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

3.2 MAFM classification

1. One-Way Machines
2. Two-Way Machines
3. Orbital Machines

3.2.1 One-way machines

Fig 3.1 One-way machines

One-way MAFM process apparatus is provided with a hydraulically actuated reciprocating piston and an
extrusion medium chamber adapted to receive and extrude medium unidirectionally across the internal
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surfaces of a work piece having internal passages formed therein. Fixture directs the flow of the medium from
the extrusion medium chamber into the internal passages of the work piece, while a medium collector collects
the medium as it extrudes out from the internal passages. The extrusion medium chamber is provided with an
access port to periodically receive medium from the collector into extrusion chamber. The hydraulically
actuated piston intermittently withdraws from its extruding position to open the extrusion medium chamber
access port to collect the medium in the extrusion medium chamber. When the extrusion medium chamber is
charged with the working medium, the operation is resumed.

3.2.2 Two-way machines

Fig 3.2 Two-Way Machines

Two-way machine has two hydraulic cylinders and two medium cylinders. The medium is extruded,
hydraulically or mechanically, from the filled chamber to the empty chamber via the restricted passageway
through or past the work piece surface to be abraded. Typically, the medium is extruded back and forth
between the chambers for the desired fixed number of cycles. Counter bores, recessed areas and even blind
cavities can be finished by using restrictors or mandrels to direct the medium flow along the surfaces to be
finished.

3.2.3 Orbital machines

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Fig 3.3 Orbital Machines

In orbital MAFM, the work piece is precisely oscillated in two or three dimensions within a slow flowing
‘pad’ of compliant elastic/plastic MAFM medium. In orbital MAFM, surface and edge finishing are achieved
by rapid, low-amplitude, oscillations of the work piece relative to a self-forming elastic plastic abrasive
polishing tool. The tool is a pad or layer of abrasive-laden elastic plastic medium, but typically higher in
viscosity and more in elastic. Orbital MAFM concept is to provide transitional motion to the work piece.
When work piece with complex geometry translates, it compressively displaces and tangentially slides across
the compressed elastic plastic self-formed pad which is positioned on the surface of a displacer which is
roughly a mirror image of the work piece, plus or minus a gap accommodating the layer of medium and a
clearance. A small orbital oscillation (0.5-5 mm) circular eccentric planar oscillation is applied to the work
piece so that, at any point in its oscillation, a portion of its surface bumps into the medium pad, elastically
compresses (5 to 20%) and slides across the medium as the work piece moves along its orbital oscillation
path. As the circular eccentric oscillation continues, different portions of the work piece slide across the
medium. Ultimately, the full circular oscillation engages each portion of the surface. To assure uniformity, the
highly elastic abrasive medium must be somewhat plastic in order to be self-forming and to be continually
presenting fresh medium to the polishing gap.

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Chapter 4

ADVANTAGE & DISADVANTAGE

4.1 Advantage
1. A very high volume of internal deburring is possible
2. MAFM deburrs precision gears
3. MAFM polishes internal and external features of various component.
4. MAFM removes recast layer from component.
5. Effective on all metallic material.
6. Controllability, repeatability and cost effectiveness
7. Less Time Consumption

4.2 Disadvantage

1. Abrasive material tends to get embedded if the work material is ductile

2. Requires closed environment
3. Requires startup holes
4. Mostly magnetic material

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Chapter 5

APPLICATION

5.1 Automotive

Fig 5.1 Internal Passage of Engine

The demand for this process is increasing among car and two-wheeler manufacturers as it is capable to make
the surfaces smoother for improved air flow and better performance of high-speed automotive engines.
MAFM process is capable to finish automotive and medical parts, and turbine engine components. Internal
passages within a turbine engine diffuser are polished to increase air flow to the combustion chamber of the
engine. The rough, power robbing cast surfaces are improved from 80-90% regardless of surface complexities.

5.2 Dies and Moulds

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Fig 5.2 Casting Dies

Since in the MAFM process, abrading medium conforms to the passage geometry, complex shapes can be
finished with ease. Dies are ideal workpieces for the MAFM process as they provide the restriction for
medium flow, typically eliminating fixturing requirements. The uniformity of stock removal by MAFM
permits accurate ‘sizing’ of undersized precision die passages.

5.3 Metal Fabricators

Components machined using MAFM technique will have smooth surface finish.

5.4 Aerospace engine and control system component

Fig 5.3 Aerospace Parts

The aerospace engine has intricated components with complex designs. These components have to machine to
utmost perfectness which is difficult in traditional machining processes but can be easily machined using
MAFM technique.

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CONCLUSION
MAFM is a well-established advanced finishing process capable of meeting the diverse finishing requirements
from various sectors of applications like aerospace, medical and automobile. It is commonly applied to finish
complex shapes for better surface roughness values and tight tolerances. But the major disadvantage of this
process is low finishing rate. The better performance is achieved if the process is monitored online. So,
acoustic emission technique is tried to monitor the surface finish and material removal. Various modelling
techniques are also used to model the process and to correlate with experimental results. But experts believe
that there is still room for a lot of improvements in the present MAFM status. A magnetic field has been
applied around a component being processed by abrasive flow machining and an enhanced rate of material
removal has been achieved. Empirical modelling with the help of response surface has led to the following
conclusions about the variation of response parameters in terms of independent parameters within the
specified range.

1. Magnetic field significantly affects both MRR and surface roughness. Therefore, more improvement in
MRR is expected at still higher values of magnetic field.

2. For a given number of cycles, there is a discernible improvement in MRR and surface roughness. Fewer
cycles are required for removing the same amount of material from the component, if processed in the
magnetic field.

3. Magnetic field and medium flow rate interact with each other. The combination of low flow rates and high
magnetic flux density yields more MRR and smaller surface roughness.

4. Medium flow rates do not have a significant effect on MRR and surface roughness in the presence of a
magnetic field.

5. MRR and surface roughness both level off after a certain number of cycles.

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REFERENCES

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machine tools and manufacture, Issue number 42 (2002), 953-959.

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367, 833, Nov 29th,1994.

3. Gorana V.K, Lal G.K, “Forces prediction during material deformation in magneto abrasive flow
machining”, Journal of manufacturing systems, Issue number 260 (2006),128-139.

4. V.K Jain, R.K Jain, “Modeling of material removal and surface roughness in magneto abrasive flow
machining process”, International Journal of Machine tool & manufacture, Issue number 39 (1999), 1903-
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5. R.E Williams, “Stochastic modeling and analysis of abrasive flow machining”, Journal of Engineering for
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6. Petri K.L, Bidanda B, “A neural network process model for magneto abrasive flow machining operations,
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8. http://www.tnmsc.cn

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