UNIT IV

ADVANCED NANO FINISHING PROCESSES

PART – A
1.Define abrasive flow machining.
Abrasive flow machining, 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.

2. What is Nano finishing process?

Nano finishing is the only operation which can make rough surfaces
in nanometers range. The ultimate precision through finishing will be where
processed where there is a change in size of sub nanometer.

3.Which is not the type of abrasive flow finishing process?

Holes drilling is one of the processes that cannot be done using
Magnetic Abrasive Flow Finishing Process.

4. What is the major difference between ER and MR fluids?

Compared items MR fluids ER fluids

Yield strengths Up to 100 3-5

range(kpa)
Operating
-45 to +150 -15 to +150
temperature range
Voltage source
requirement 12 – 24 V 2 – 5 KV
Current
requirements 1-2 A 1-10 MA
5.Classify AFM.
AFM is classified into three categories, they are,
• One way AFM
• Two way AFM
• Orbital AFM.

6. Summarize the components of AFM process.

There are three major elements of the AFM system: the tooling, the
machine, and the medium.

7. List the process input parameters of AFM.

Process Parameters,
• Flow Rate – 11.3 to 378 L/min. (3 – 100 GPM)
• Cycles – 3 to several hundred
• Pressure – 0.69 – 22 MPa (100 – 3200 psi)

8. Quote the operating range of AFM.

With AFM, one can measure the force between atoms at the tip and the
sample which are located as close as 0.1–100 nm.

9.Compare the difference between one way and two way AFM.

10. List the advantages of one way AFM.

By using AFF deburring, polishing and radiusing are conducted
in one operation.
• This process can finish in accessible area.
• AFF is suitable for batch production.
• It is a very fast method.
• This method provides better accuracy and high efficiency.
• Media temperature control generally not required.
 • Excellent process control and quick change tooling.

11.Summarize the applications of AFM.

It is used for finishing operations mainly in the industries related to
the manufacturing of aerospace, automotive, semiconductor, medical parts,
etc.
• It also improves the mechanical fatigue strength of blades, disks,
hubs, shafts, etc.
• It is very useful for finishing of the following parts:
• Extrusion dies (improves die performance and life)
• Nozzle of flame cutting torch
• Airfoil surfaces of impellers of turbine
• Deburring of aircraft valve bodies and spools.
• Removing recast layer after EDM or LBM.

12.Which ratio defines the etch factor?

Etch factor is defined as the ratio of undercut to etching depth

13. List the types of surface finishing.

Abrasive blasting, Sandblasting, Burnishing, Grinding, Honing, Mass
finishing, Tumble finishing, Vibratory finishing, Polishing, Buffing, Lapping.

14. Define Chemical-mechanical polishing.

• Demands for high quality surface finish, dimensional and form
accuracy are required for optical surfaces and it is very difficult to
achieve this using conventional grinding methods.
• ELPD is new and efficient method that uses a metal bonded diamond
grinding wheel to achieve a mirror surface finish especially on hard
and brittle materials.

15 Define Damascene process.

16 Express the use of PVA in CMP.

17 Summarize the role of slurry in CMP process.

During the CMP process, a wafer surface is polished for
planarization using a slurry and a polishing pad. The abrasive particles in the
slurry grind against the sample surface, loosening material. The chemicals in
the slurry then etch and dissolve the material.

18 Quote any two applications of CMP.

Applications :
▪ This process is used for grinding of silicon surfaces in
semiconductor industry.
▪ This process produces nano surface finish on glass and
ceramics.
▪ It also helps in production of aspherical surfaces for
lenses and moulding dies in optical industry.
▪ It is used for precision grinding of bearing steel.

19 List any two advantages of CMP.

Advantages :
• Good surface finish
• High surface accuracy
• Low subsurface damage

20 What is meant magnetorheological finishing?

Magneto rheological finishing process, a convex, flat, or concave work
piece is positioned above a reference surface.
A MR fluid ribbon is deposited on the rotating wheel rim. By applying
magnetic field in the gap, the stiffened region forms a transient work zone or
finishing spot.

21 List the components of MR fluid.

 MR-Fluids are suspensions of micron sized magnetizable particles
such as carbonyl iron, dispersed in a non- magnetic carrier medium like
silicone oil, mineral oil or water.

22 Describe the desired properties of MR fluid.

The MR-polishing fluid has following merits:-
1. Its compliance is adjustable through the magnetic field.
2. It carries heat and debris away from the polishing zone.
3. It does not load up as in grinding wheel.
4. It is flexible and adapts the shape of the part of the work piece
which is in its contact.

23 Quote any two advantages of MRF.

Resistance to applied shear strain by chains is responsible for material
removal
• Zone of finishing is restricted to a spot
• Most efficient and for high precision finishing of optics
• MRF makes finishing of free form shapes possible for first
time.
24 List the limitations of MRF process.

25 List the applications of MRAFF process.

Possible application areas of MRAFF process are
(a) Aerospace
(b) Medical
(c) Automotive