Department of Mechanical Engineering

Shri Sant Gajanan Maharaj College of Engineering

Seminar
on
“ADVANCE ABRASIVE FINISHING”

Guide: Prof. K. R. Gandhare

Name : A. K. Lahase
Roll No: 4M 29
 Content
 What is Manufacturing?
Importance's Of Manufacturing
Classification of Manufacturing Processes
Importance of Machining and Finishing.
 Introduction to Abrasive Particles
Types of Abrasives particles.
Abrasive particles: Fabrication Method
 Abrasive flow machining.
Introduction.
Principal of Working and Operation.
Experimental Setup.
Advantage.
Disadvantages.
Application.
 Content
• MAGNETIC ABRASIVE FINISHING
Introduction.
Principal of Working and Operation.
Experimental Setup.
Advantage.
Disadvantages.
Application.
 What is Manufacturing?
• The Successful Creation of Men’s, Material, Welfare (MMW)
depends Mainly on
 Availability of Nature Resources
 Exertion of Human Effort (HE); Both physical And Mental.
 Development and Use Of Power Tools And Machine Tools.

Production
RAW FINISHED
MATERIAL ENERGY PRODUCT
Process
 Importances Of Manufacturing

ENERGY

MACHING

ENERGY

FINISHING

This particular process of conversion of Raw

materials into the Final Product is nothing, but
the Manufacturing.
Classification of Manufacturing Processes :-
• Machining.
• Forming
• Joining Among these- Machining
• Sheet Metal Processing. & Finishing Process are
the ones that come under
• Casting. ABRASIVE PROCESS
• Powder Metallurgy.
• Finishing.
Difference Between Abrasive Finishing and Abrasive Machining
In Abrasive Machining How much material we going to Remove, but in
Abrasive Finishing We don’t bother about how much material to be remove We
are more Condensed only about WHAT IS SURACE FINISHING.
Importance of Machining and Finishing.
•In order to sell your product
into the market, you need good
aesthetic appeal, you need
perfect tolerances and other
things for that purpose you Before After
should go for machining and
finishing of this particular
things .
 Introdction to Abrasive Particles.
• Abrasive particles are essential for polishing. The most
important property of an abrasive is its hardness. For
abrasive grains to effectively cut, they must be significantly
harder than the work piece material.
• They can be grouped based on their hardness into two
categories:
Conventional Super
Abrasives Abrasives.

 Made Of Materials That Exist In  Much harder than conventional

Naturally. abrasives.
 Abundant And Cheap. Much more expensive.
 Suitably Machine Most Materials.
Commonly Used Abrasives Are Listed Below.

• Alumina Oxide (Al2 O3 )  Most of the Abrasive Particles are

• Silicon Carbide (Sic)
• Boron Carbide (B4C)
• Cubic Boron Nitride (CBN)
• Diamond
Ceramic (Brittle in Nature)
Advance Abrasive Particles with
High Hardness are Called
Super Abrasive
Abrasive particles: Fabrication Method
Abrasive Ball Cylindrical
Ball Milling
Shell

Abrasive
Particle

Abrasive Particle (Finish Product)

 Fig. 1.2 Fabrication Method in Mass Production

Fabrication Method in Mass Production

 NEED 0f Advance finishing:-
In the era of nanotechnology , high finishing methods are of
most importance and are need of present Scenario.
1. To reduce the friction.
2. Improve fatigue life.
3. Reduces generation of crack formation.
4. Eliminates Vibration.
5. Less Susceptible to corrosion.
6. To provide Sharpness E.g. Cutting Tools

1 2
 Introduction to abrasive finishing processes

To finish the surfaces in the nanometer range. It is required to

remove the material in the form of atoms or molecules
individually or in the groups.
 Classification of advanced finishing processes :-
 Conventional Finishing Processes.
 Polymers Assisted Abrasive Finishing Processes.
 Magnetic Field Assisted Finishing Process.
(magnetic Field to control force on Abrasive
particles)
• Magnetic abrasive finishing
Finishing Ability of Various Abrasive
Finishing Processes:-

• 22 lect
• 7.39
 Ultra-piston machining
Narto Taniguchi machining processes are classified into
THREE categories :-

Conventional
Machining
Precision
Machining.
Ultra-piston
Machining.

Year
 ABRASIVE FLOW MACHINING

• INTRODUCTION
• AFF was developed by Extrude hope
corporation USA in 1960’s.
• With today's focus on total automation in the
flexible manufacturing system, the abrasive
flow machining process offers both automation
and flexibility .
• This process was developed basically to
debarred, polish and radius difficult to reach
surfaces and edges by flowing abrasive laden
polymer, to and fro in two vertically opposed
cylinders.
• It Produces Predictable, Repeatable and
Consistent Results. Up to 90% times can be
save by using AFF as compared to hand
Finishing Operation.
 PRINCIPLE OF OPERATION AND WORKING:
In this process, a semi-solid media is utilized which comprises
of a carrier in the form of a polymer base containing
abrasive powders in a desired proportion, which is extruded
under the given pressure across the surface, which is to be
finished.
Forces in AFF Process :-

Why only Viscoelastic Medium ?

•Pressure is Acting in Viscoelastic medium.

•Viscoelastic Medium Consist two
components –

Viscous Comp. Elastic Comp.

Axial Forces Radial Forces

Pushes indent abrasive Indent abrasive

particles in axial particles in the
direction. workpiece surface.
 EXPERIMENTAL SETUP
Basic Three Elements of AFF Process
Machine Setup:-
•Hydraulically operated cylinders-
used for back and forth motion of
abrasive putty through workpiece.
Tooling:-
 jig and Fixture-Hold part in
position and contain media and
direct its flow.
Medium (AbrasiveMedium)
•Consists of Base material
+Abrasive grits+Rheological
additives (such as softeners,
plasticizers, hardness
functionalizes and so on.)
 ADVANTAGES
• Surface finish as good as 50micron.
• Dimensional tolerances as good as 0.005
mm
• Good finishing on the difficult to finish
internal shapes.
• Nano metrical surface finish can be
achieved.
• Complex geometry shapes can be finished.
• Process multiple passage on a single work
piece or multiple parts simultaneously.
 DISADVANTAGES
• Low material removal rate.
• Production time is very high so possibility of
change in media viscosity is maximum.
• High Media cost.(Enhance the product cost)
• Cannot control Abrading Forces during the
finishing.
• Clean and finish only along the lay direction but
can not correct.
 Tapper Problem
 out of roundness
 Bell mouth in case of parts whose length/dia is high
 barrel
 boring marks a lefts on surfaces
 APPLICATION
• AFM in Aerospace Industry.(valvesof aircraft)
• Enhanced uniformity and surface quality of finished components
• Increased engine performance.(Injection of diesel engine)
• Increased flow velocity and volume
• Improved fuel economy and reduced emissions
• Extended work piece life by reducing wear
• Eliminate the surface imperfections where dangerous contaminates can
reside
• Improved functionality, durability and reliability of medical component.

Finished, Deburring and Radiusing

MAGNETIC ABRASIVE FINISHING
INTRODUCTION:
• Magnetic abrasive finishing (MAF) can be defined as a process by
which surface is finish by removing the material in the form of
debris particles by magnetic abrasive particles in the presence of
magnetic field in the finishing zone.
• Magnetic Abrasive Finishing can be defiend as Finishing Process in
which flexible magnetic brush, composed of magentic abrasive
partical does the Finishing Operation.
• Magnetic Abrasive Particles are prepared by mixing iron particles
(magnetic) with abrasives (Like SiO2,AL2O3 and so on)
PRINCIPLE OF OPERATION AND
WORKING:
PRINCIPLE OF OPERATION AND WORKING:

Cylindrical surface Plane surfaces

 MAF Experimental setup :-

• 25,43
Before and After MAF
 ADVANTAGES:

• Able to attain wide range of surface characteristics

by care full selection of magnetic particles
• Enhance surface characteristic such as wet ability or
reducing friction
• The Finishing tool requires neither compensation
nor Dressing
• This Method can finish Ferromagnetic material as
well as non Ferromagnetic material
• Capability to accessing hard to reach areas.
• Due to the flexible magnetic abrasive brush, it can
finish any symmetric work piece shape , if
electromagnetic designed accordingly
 DISADVANTAGES:

• It is difficult to implement Magnetic Abrasive

finishing in mass production operation
• Not applicable for some ordinary Finishing task
where conventional finishing technique can be
easily implemented.
• Time consuming process.
• The cost process is high
 APPLICATION:

• Cutting Tool.
• Turbine Blade.
• Air foil.
• Optics.
• Sanitary pipes.
• Food Industries.
• Capillary tubes, Needles, Biopsy needles in
Medical Field.
 References
[1] “Introduction to Abrasive Machining and Finishing Processes” Dr.
Mamilla Ravi Sankar Department of Mechanical Engineering Indian
Institute of Technology, Guwahati
https://nptel.ac.in/courses112103250//21, Aug -2019.
[2] “Magnetic Abrasive Finishing- A Review” By Harish Kumar, Sehijpal
Singh, Pradeep Kumar IJERT Vol.2 Issue 3, March-2013.
[3] “To study the Effect of Various Parameters on Magnetic Abrasive
Finishing” By Mithlesh Sharma, Devinder Pal Singh IJRMET Vol. 3,
Issue 2, May-Oct 2013.
[4] “Study of Abrasive Finishing in free-form surface operation using the
Taguchi method” By ChingTien Lin, Lieh-Dai Yang, and Han-Ming
Chow.
[5] “Study of Mechanically Alloyed Magnetic Abrasive in Magnetic
Abrasive Finishing” By M.G.Patil, Kamlesh Chandra, P.S.Mishra
IJS&ERT Vol.3 Issue 2, October-2012.
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