Magneto Abrasive Flow Machining Project Report

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ABSTRACT

This report discusses how using a magnetic field around the work piece in AFM can improve surface roughness and material removal rate. A setup for a composite process known as magneto abrasive flow machining (MAFM) has been developed, and the effect of key parameters on the process’s performance has been studied. When this process is used to finish-machine brass components, relationships are formed between the material removal rate and the percentage improvement in surface roughness.

Magneto Abrasive flow machining (MAFM) is a relatively new non-conventional machining process with excellent capabilities for finishing inaccessible regions of a component. It has been used successfully for precision component deburring, radiusing, and removing recast layers. For a wide range of components, high levels of surface finish and sufficiently close tolerances have been achieved. A semi-solid medium made up of a polymer-based carrier and abrasives in a typical proportion is extruded under pressure through or across the surfaces to be machined in MAFM. When the medium is restricted in any way, it acts as a deformable grinding tool. In most cases, a special fixture is required to create a restricted passage or to direct the medium to the desired locations in the work piece.

ADVANTAGES OF MAGNETO ABRASIVE FLOW MACHINING

1. A very high volume of internal deburring is possible.

2. MAFM deburrs precision gears.

3. MAFM polishes internal and external features of various components.

4. MAFM removes recast layer from components.

5. Effective on all metallic materials.

6. Controllability, repeatability and cost effectiveness.

7. Less Time Consumption.

LIMITATIONS OF MAGNETO ABRASIVE FLOW MACHINING

1. Abrasive materials tend to get embedded, if the work material is ductile.

2. Require closed environment.

3. Require start up hole.

4. Mostly Magnetic materials.

APPLICATIONS OF MAGNETO ABRASIVE FLOW MACHINING

1. Automotive

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.

2. Dies and Moulds

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.

3. Laser Shops with materials as titanium, and steel (Thicker metal or composites).

4. Prototype, R&D, Maintenance and Repair Shops.

5. Controls Just-in-Time inventory requirements.

6. Metal Fabricators: Offer “clean edge” plate work.

7. Aerospace engine and control system components.

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