Advanced Finishing Processes

Advanced Finishing Processes

(AFPs)
➢ Abrasive Flow Machining (AFM)
➢ Magnetic Abrasive Finishing (MAF)
➢ Magneto Rheological Finishing (MRF)
➢ Magneto Rheological Abrasive Flow Finishing
(MRAFF)
➢ Magnetic Float Polishing (MFP)
➢ Elastic Emission Machining (EEM)
➢ Ion Beam Machining (IBM)
➢ Chemical Mechanical polishing (CMP)
 Magnetic Float Polishing
❖ Ceramics are extremely sensitive to surface defects resulting from grinding
and polishing processes. Fatigue failure of ceramics is driven by surface
imperfections.

❖ For this gentle and flexible polishing conditions like low level of controlled
forces and use of abrasives softer than work material are required.
❖ A magnetic fluid containing fine abrasive grains and extremely fine
ferromagnetic particles in a carrier fluid such as water or kerosene fills
the aluminium chamber.

❖ A bank of strong electromagnets is arranged alternately north and south

below the chamber.

❖ On the application of magnetic field the ferro fluid is attracted downward

towards the area of higher magnetic field and an upward buoyant force is
exerted on non-magnetic material(abrasive grains, ceramic balls, and
acrylic float) to push them to the area of lower magnetic field.
❖ Drive shaft is fed down to contact the ball and presses them down to reach
the desired force level.

❖ The balls are polished by the relative motion between the balls and the
abrasives under the influence of buoyant force and resistance.

❖ Both higher material removal rate and smoother surface in this polishing
method, are attained by stronger magnetic field and finer abrasives.
❖ Conventional polishing of ceramic balls takes considerable time(12-15days)
to finish a batch of ceramic balls because of low polishing speeds and use
of expensive diamond abrasive at high loads can result in scratches, and
micro cracks.

❖ Magnetic Float polishing is used to finish 9.5 mm diameter Si3N4 balls.

❖ The surface finish obtained was 4 nm Ra and 40 nm Rmax. Finished

surfaces relatively free of scratches, micro cracks, etc. were obtained.
 Elastic Emission Machining
❖ Uses ultra fine particles to collide with workpiece surface.
❖ Finish surface by atomic scale elastic fracture & directly by removing
atoms & molecules from surface without plastic deformation.

❖ Workpiece is submerged in slurry of abrasive particles (ZrO2 or Al2O3) and

water.

❖ Polyurethane ball(56 mm dia) mounted on shaft, driven by motor, is

used to apply working pressure.
❖ Material removed by erosion of surface atoms by bombardment of abrasive
particles.
Elastic Emission Machining
(contd..)
Elastic Emission Machining
(contd..)
 Elastic Emission Machining
(contd..)

❖ It is able to remove material at the atomic level by mechanical methods.

❖ Surface roughness as low as 0.5 nm have been reported on glass.
Thank you