Abstract

This process provides improvement in surface roughness and material removal rate,
polish intricate geometries. The process has found applications in a wide range of
fields such as aerospace, defence, and surgical and tool manufacturing industries.
Extrusion pressure, flow volume, grit size, number of cycles, media, and work piece
configuration are the principal machining parameters that control the surface finish
characteristics. Recently there has been a trend to create hybrid processes by
merging the AFF process with other non-conventional processes. This has opened
up new vistas for finishing difficult to machine materials with complicated shapes
which would have been otherwise impossible. These processes are emerging as
major technological infrastructure for precision, meso, micro, and nano scale
engineering. This review provides an insight into the fundamental and applied
research in the area and creates a better understanding of this finishing process,
with the objective of helping in the selection of optimum machining parameters for
the finishing of varied work pieces in practice.MAFM is a new non-conventional
machining technique .It produces surface finishes ranging from rough to extremely fine.
Here chips are formed by small cutting edges on abrasive particles.The use of magnetic
field around the work piece. It deflects the path of abrasive flow. Here ‘Microchipping’
of the surface is done.

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 INDEX
Sr. No Topic Page No
1 Introduction 5

7
2 Literature View

3 Non Traditional Flow Machining 8

4 Experimental Set-Up 9

5 Process Parameters 11

6 Principle 12

7 Abrasive Medium 14

8 MAFM Machines 15

9 Ultra-High Pressure Pump 18

10 Advantages 19

11 Limitations 20

12 Applications 21
23
13 Summary

24
14 References

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 List of Figure

Sr. No. Name Page

1 The Workpiece 10

2 (a) Off-state MR fluid particles (b) Aligning in an applied 12

magnetic field

3 Principle of Material Removal Mechanism 13

4 Mechanism of Magneto Abrasive Flow Machining 14

5 Unidirectional MAFM Process 15

6 Two–way MAFM Process 16

7 Orbital MAFM Process (a) Before start of finishing (b) 17

While finishing

8 An ultra-high pressure pump 18

9 Surface finish improvement before and after on (a) 22

internal passages within turbine engine diffuser (b)
medical implants (c) complete automotive engine parts.

1. INTRODUCTION
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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).

Problem Definition

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,
radiusing, and removing recast layers of precision components. High levels of surface
finish and sufficiently close tolerances have been achieved for a wide range of
component 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.

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Background

Extrude Hone Corporation, USA, originally developed the AFM process in 1966. Since
then, a few empirical studies have been carried out and also research work regarding
process mechanisms, modeling of surface generation and process monitoring of AFM
was conducted by Williams and Rajurkar during the late 1980s. Their work was mainly
related to online monitoring of AFM with acoustic emission and stochastic modeling of
the process. Loveless et al. and Kozak et al investigated the effect of previous machining
process on the quality of surface produced by AFM and the flow behavior of the medium
used in the process. Fletcher and others reported studies on the rheological properties and
the effect of temperature of the medium used in AFM. Przyklenk conducted parametric
studies of AFM. Research work concerning mathematical modeling, simulation of
material removal and surface generation with the help of finite element and neural
networks was presented by different researchers. Steif and Haan suggested the presence
of ‘dispersive stresses’, which enable wear of the surface during abrasive flow
processing. The dispersive stresses are generated because of the difference between
stresses acting on abrasive particles and those acting in the surrounding medium. Jones
and Hull reported the modification of existing AFM by applying ultrasonic waves in the
medium for machining blind cavities. The orbital flow machining process suggested by
Gilmore 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. Rajurkar and Kozak have described around 15 various processes under this
category.

Aim and Specific Objectives

This report discusses the possible improvement in surface roughness and material
removal rate by applying a magnetic field around the work piece in AFM. A set-up has

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been developed for a composite process termed magneto abrasive flow machining
(MAFM), and the effect of key parameters on the performance of the process has been
studied. Relationships are developed between the material removal rate and the
percentage improvement in surface roughness of brass components when finish-
machined by this process.

Method

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. This report presents the preliminary results of an ongoing 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. Shinmura and Yamaguchi and more recently
Kim et al., Kremen et al. and Khairy have reported studies on this process. The process
under investigation is the combination of AFM and MAF, and is given the name magneto
abrasive flow machining (MAFM).

2. LITERATURE VIEW
AFM was developed in 1960s as a method to deburr, machining. This provides
improvement in surface roughness and material removal rate, polish intricate geometries.

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The process has found applications in a wide range of fields such as aerospace,
defence, and surgical and tool manufacturing industries. Extrusion pressure, flow
volume, grit size, number of cycles, media, and work piece configuration are the
principal machining parameters that control the surface finish characteristics.
Recently there has been a trend to create hybrid processes by merging the AFF
process with other non-conventional processes. This has opened up new vistas for
finishing difficult to machine materials with
Complicated shapes which would have been otherwise impossible. These processes
are emerging as major technological infrastructure for precision, meso, micro, and
nano scale engineering. This review provides an insight into the fundamental and
applied research in the area and creates a better understanding of this finishing
process, with the objective of helping in the selection of optimum machining
parameters for the finishing of varied work pieces in practice.MAFM is a new non-
conventional machining technique .It produces surface finishes ranging from rough to
extremely fine. Here chips are formed by small cutting edges on abrasive particles.The
use of magnetic field around the work piece. It deflects the path of abrasive flow. Here
‘Microchipping’ of the surface is done.

3. NON-TRADITIONAL MACHINING

In present world of competition, product quality is main requirement of the customer.

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It is impossible to get required degree of accuracy and quality with conventional methods
of machining. So it is required to move towards the application of non-traditional
methods.
The newer machining processes, so developed, are often called modern machining
process or unconventional machining process. These are unconventional in the sense that
the conventional tools are not employed for material removal. The energy in its direct or
indirect form is utilized. Some of the non-traditional processes are:
1. Electro Chemical Machining (ECM)
2. Electro Discharge Machining (EDM)
3. Ion Beam Machining (IBM)
4. Laser Beam Machining (LBM)
5. Plasma Arc Machining (PAM)
6. Ultrasonic Machining (USM)
7. Magnetic Abrasive Flow Machining (MAFM), etc.
These non-traditional methods cannot replace the conventional machining processes and
a particular method, found suitable under the given conditions, may not be equally
efficient under other conditions. A careful selection of the process for a given machining
conditions is therefore essential. Furthermore, the machining process has to safely
remove the material from work piece without inducing new sub-surface damages, the
machining of work piece by means of magneto abrasive flow machining (MAFM) could
be such a process. Unlike traditional grinding, lapping or honing processes with fixed
tools, MAFM applies no such rigid tool with important advantage of subjecting the work
piece to substantially lower stresses.

4. EXPERIMENTAL SET-UP
MAFM set - up.

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An experimental set-up is designed and fabricated. It consisted of two cylinders
containing the medium along with oval flanges. The flanges facilitate clamping of the
fixture that contains the work piece and index the set-up through 180° when required.
Two eye bolts also support this purpose. The setup is integrated to a hydraulic press. The
flow rate and pressure acting on piston of the press were made adjustable. The flow rate
of the medium was varied by changing the speed of the press drive whereas the pressure
acting on the medium is controlled by an auxiliary hydraulic cylinder, which provides
additional resistance to the medium flowing through the work piece. The resistance
provided by this cylinder is adjustable and can be set to any desired value with the help of
a modular relief valve The piston of the hydraulic press then imparts pressure to the
medium according to the passage size and resistance provided by opening of the valve.
As the pressure provided by the piston of the press exceeds the resistance offered by the
valve, the medium starts flowing at constant pressure through the passage in the work
piece. The upward movement of the piston (i.e. stroke length) is controlled with the help
of a limit switch. At the end of the stroke the lower cylinder completely transfers the
medium through the work piece to the upper cylinder. The position of the two cylinders is
interchanged by giving rotation to the assembly through 180° and the next stroke is
started. Two strokes make up one cycle. A digital counter is used to count the number of
cycles. Temperature indicators for medium and hydraulic oil are also attached.

The Fixture.
The work fixture was made of nylon, a non-magnetic material. It was specially designed
to accommodate electromagnet poles such that the maximum magnetic pull occurs near
the inner surface of the work piece.

The Electromagnet.

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The electromagnet was designed and fabricated for its location around the cylindrical
work piece. It consists of two poles that are surrounded by coils arranged in such a
manner as to provide the maximum magnetic field near the entire internal surface of the
work piece.

The Abrasive Medium.

The medium used for this study consists of a silicon based polymer, hydrocarbon gel and
the abrasive grains. The abrasive required for this experimentation has essentially to be
magnetic in nature. In this study, an abrasive called Brown Super Emery (trade name),
supplied by an Indian company, was used. It contains 40% ferromagnetic constituents,
45% Al2O3 and 15% Si2O3.

Figure 1: The Workpiece

5. PROCESS PARAMETERS

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Following process parameters were hypothesised to influence the performance of
MAFM:

1. Flow rate (volume) of the medium,

2. Magnetic flux density,
3. Number of cycles,
4. Extrusion pressure,
5. Viscosity of the medium,
6. Grain size and concentration of the abrasive,
7. Work piece material,
8. Flow volume of the medium, and
9. Reduction ratio.

6. PRINCIPLE

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The volume of abrasive particles is carried by the abrasive fluid through the work piece.
Abrasives are impinged on the work piece with a specified pressure which is provided by
the piston and cylinder arrangement or with the help of an intensifier pump. The pressure
energy of the fluid is converted into kinetic energy of the fluid in order to get high
velocity.
When a strong magnetic field is applied around the work piece, the flowing abrasive
particles (which must essentially be magnetic in nature) experience a sideways pull that
causes a deflection in their path of movement to get them to impinge on to the work
surface with a small angle, thereby resulting in microchipping of the surface. The
magnetic field is also expected to affect the abrasive distribution pattern at the machining
surface of the work piece. The particles that otherwise would have passed without
striking the surface now change their path and take an active part in the abrasion process,
thus causing an enhancement in material removal. It is to be mentioned here that although
the mechanical pull generated by the magnetic field is small, it is sufficient to deflect the
abrasive particles, which are already moving at considerable speed. Therefore it appears
that, by virtue of the application of the magnetic field, more abrasive particles strike the
surface. Simultaneously, some of them impinge on the surface at small angles, resulting
in an increased amount of cutting wear and thereby giving rise to an overall enhancement
of material removal rate.

(a) (b)
Figure 2: (a) Off-state MR fluid particles (b) Aligning in an applied magnetic field.

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 Figure 3: Principle of Material Removal

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 7. ABRASIVE MEDIUM
The mainly used abrasive media is a Silicon based polymer, hydrocarbon gel and the
abrasive grains.The abrasive required is essentially magnetic in nature for the proper
machining process to take place. An abrasive called Brown Super Emery (trade name),
supplied by an Indian company is normally used. It contains 40% ferromagnetic
constituents, 45% Al2O3 and 15% Si2O3. SiC with silicon gel is also used as an abrasive
media.Also diamond coated magnetic abrasives can be used to finish ceramic bars.

Figure 4: Mechanism of Magneto Abrasive Flow Machining

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 8. MAFM MACHINES
MAFM Machines are classified into 3, namely:-
1. One-Way Machines
2. Two-Way Machines
3. Orbital Machines
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 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.

Figure 5 Unidirectional MAFM Process

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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.

Figure 6: Two–way MAFM Process

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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.

Figure 7: Orbital MAFM Process (a) Before start of finishing (b) While finishing.

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 9. ULTRA-HIGH PRESSURE PUMPS.
High pressure pumps are an alternative to create pressure. The intensifier pump creates
pressures high enough for machining. An engine or electric motor is used which drives a
hydraulic pump. Pressures from 1,000 to 4,000 psi (6,900 to 27,600 kPa) are achieved
which is given into the intensifier cylinder. Hydraulic fluid pushes a large piston to
generate a high force.The plunger pressurizes fluid to a level proportional to the relative
cross-sectional areas of the large piston and the small plunger.

Figure 8: An ultra-high pressure pump

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 10. ADVANTAGES

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.

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 11. LIMITATIONS

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.

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 12. APPLICATIONS

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.

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.

The original 2 micron ∑Rs (EDM Finish) is improved to 0.2 micron with a stock removal
of (EDM recast layer) 0.025 mm per surface.

Laser Shops with materials as titanium, and steel

(Thicker metal or composites).

Prototype, R&D, Maintenance and Repair Shops.

Controls Just-in-Time inventory requirements.

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Metal Fabricators: Offer "clean edge" plate work.

Aerospace engine and control system components.

Figure 9: Surface finish improvement before and after on (a) internal passages within
turbine engine diffuser (b) medical implants (c) complete automotive engine parts.

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 13. SUMMARY
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. The slope of the
curve indicates that MRR increases with magnetic field more than does 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.

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 14. REFERENCES
1. Singh S, Shan H. S, “Development of magneto abrasive flow machining process”,
International Journal of machine tools and manufacture, Issue number 42 (2002),
953-959.

2. L.J Rhoades, Kohut T.A, Nokovich N.P, Unidirectional abrasive flow machining,
US patent number 5, 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), 1903-1923.

5. R.E Williams, “Stochastic modeling and analysis of abrasive flow machining”,

Journal of Engineering for Industry, Issue number 114 (1992), 74-81.

6. Petri K.L, Bidanda B, “A neural network process model for magneto abrasive flow
machining operations, Journal of manufacturing systems, Issue number 17 (1998),
52-64.

7. J S, Jain V.K, “Design and development of the magneto rheological abrasive flow
finishing process”, International Journal of machine tool & manufacture, Issue
number 44 (2004), 1019-1029.

8. http://www.tnmsc.cn

9. http://www.google.com.in

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