CH-4, Micro/Nano Finishing Process

Reduction in Friction-Aerospace Torque and Fuel Economy-Engine

Eliminate imperfection
Why Nano finishing is required?
 Wear resistance  Corrosion and oxidation resistance
 Mechanical properties (fatigue life,  Aesthetic appearance
toughness, etc.)  and many others
 Optical properties
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Nanofinishing of Aircraft’s blade bearing

Final finishing operations in manufacturing of precise parts are always of concern owing to their
most critical, labour intensive and least controllable nature. The machining processes were
classifieds into three categories on the basis of achievable accuracy viz. Conventional machining,
precision machining and ultraprecision machining.
The need for high precision in manufacturing was felt by manufacturers worldwide to improve
interchangeability of components, improve quality control and longer wear/fatigue life.
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Nanotechnology is the target of ultra-precision machining because the theoretical limit of

accuracy in machining of substance must be the size of an atom or molecule of the substance.
With the advent of new materials, manufacturing is facing challenges in machining them to meet
their functional requirements. As the demand moves from the micro technology (1µm accuracy
capability) to the nanotechnology region (1 nm accuracy) the systems engineering demands rapid
increase in stringency and complexity
The ultimate precision obtainable through finishing is when chip size approaches atomic size (~
0.3 nm). To finish surfaces in nanometre range, it is required to remove material in the form of
atoms or molecules individually or in the groups
 Some processes like Elastic Emission Machining (EEM) and Ion beam Machining (IBM)
work directly by removing atoms and molecules from the surface.
 Other processes based on abrasive wear remove them in clusters. On the basis of energy
used, the advanced finishing processes (AFPs) can be broadly categorized into
mechanical, thermoelectric, electrochemical and chemical processes
The Nano finishing processes can be classified in the following categories:
A. Traditional Nano finishing processes
1. Grinding
2. Honing
3. Lapping
B. Advanced Nano finishing processes
1. Abrasive flow finishing (AFF)
2. Elastic emission finishing (EEF)
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3. Magnetic abrasive Finishing (MAF) and Magnetorheological finishing (MRFF)
4. Focused ion beam finishing (FIBF)
1. Abrasive flow finishing (AFF)
 Surface finish determines the wear resistance of the component and power loss due to
friction.
 If the surface is not smooth, it can lead to component failure because of crack initiation
from the surface. Advancing technology made the miniaturisation of components a
necessity.
 Surface roughness becomes more important as there is miniaturisation of the component
dimensions.
Even a slight alteration in the dimension can altogether change component functionality
Operating range of AFM
 Easy flowability
 Better self deformability
 Fine abrading capability
 Layer thickness of material removed is, order of about 1£gm to 10 µm
 Best surface finish that has been achived as 50 nm
 and tolerances +/- 0.5 µm
Operating range of AFM Principal finishing parameters that determine the end finish of the
component during the AFF operation are as follows:
One-Way AFM
One-way flow AFM processing pushes abrasive media through the work piece in only one
direction, allowing the media to exit freely from the part

The advantages of One Way AFM

1. Faster cycle processing 3. Media temperature control generally
2. Easy clean-up not required
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4. Able to process larger parts 6. Accurately replicates air or liquids
5. Simpler tooling and part change- natural flow
over 7. Does not encapsulate workpart in
media
Two-Way AFM
 The typical two-way flow AFM process uses two vertically opposed cylinders to extrude
an abrasive media back and forth through or around passages formed by the workpiece
and tooling.
 Abrasive action occurs wherever the media enters and passes through the most restrictive
passages.

Schematic diagram of AFF process experimental setup

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Advantages of Two-Way AFM
i. Excellent process control
ii. Can finish both ID and OD of component
iii. Good control of radius generation
iv. Fully automated system capabilities
v. Faster setup & quick-change tooling
vi. Faster change-over of media
Orbital AFM
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 (similar to that used in two
way abrasive flow finishing), but typically higher in viscosity and more in
elastic

Before start of finishing

While finishing
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Principal finishing parameters that determine the end finish of the component during the AFF
operation are as follows:
1. Setting parameters: These include the input parameters, which are given before the start
of the AFF process, e.g. extrusion pressure, medium flow velocity, number of AFF cycles
and flow volume.
2. Tooling: The design of the fixture depends on the workpiece to be finished. Some of the
basic functions of the fixture/tooling are as follows
a. To position the workpiece at the desired location and hold it tightly.
b. To have enough strength in order to withstand the forces acting during finishing
operation.
c. It should act as a restriction passage for guiding the abrasive medium across the
workpiece properly without any leakage through them.
3. Medium
The AFF medium plays a vital role in the finishing of workpiece. The medium mainly
comprises of the base polymer, which is viscoelastic in nature; additives (plasticisers,
softeners) and abrasive particles.
A good AFF medium should be mechanically stable, chemically non-reactive and self-
deformable and have good fluidity and good abrading ability. The composition and
quantities of all these ingredients depend on the dimensions of the pathway through
which the medium is to be extruded for finishing the component.
Characteristics of AFF process are the following
 Deburr, polish and radius difficult to reach surfaces.
 Produces radii even on complex edges.
 Surface roughness is reduced by 90% on cast, machined or electric discharge machined
surfaces.
 AFF can simultaneously process multiple parts or many areas of a single workpiece.
 As there is no pre-defined relative motion of the tool relative to the workpiece,
inaccessible areas and complex internal passages can be finished economically as well as
effectively.
 It is easy to integrate AFF in any automatic manufacturing environment.
 Automatic AFF systems are capable of handling thousands of parts per day, greatly
reducing labour costs by eliminating tedious handwork.
 By understanding and controlling the process parameters, AFF can be applied to an
impressive range of finishing operations by changing tooling, process settings and
abrasive medium.
 It is possible to control and select the intensity as well as the location of abrasion through
fixture design, medium selection and process parameters
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Mechanism of Material Removal during the AFF Process

The medium used in finishing of workpieces during the AFF process is composed of a soft base
polymer carrier, additives and fine abrasive particles.
The base polymer is viscoelastic in nature; i.e. it contains both elastic as well as viscous
properties when undergoing deformation. It acts as a binder for holding abrasive particles.
When extrusion pressure (P) is applied on the medium, the elastic component of the medium
results in generation of radial force (FR), while viscous component generates axial force (FA).
FR is responsible for indentation of abrasive particles in the workpiece surface while FA pushes
the indented abrasive particles in the axial direction to remove the material by shearing action in
the form of microchip.

Application of AFM
Aerospace Industry
 Improved surface quality
 Enhanced high cycle fatigue strength
 Optimized combustion and hydraulics
 Increased airflow
 Extended component life
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Automotive Industry
 Enhanced uniformity and surface quality of finished components
 Increased engine performance
 Increased flow velocity and volume
 Improved fuel economy and reduced emissions
 Extended work piece life by reducing wear and stress surfaces

Dies and mold Industry

 Reduced production costs
 Increased production throughput
 Enhanced surface uniformity, finish and
 cleanliness
 Improved die performance and extend life of dies and molds
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Medical Industry
a. Eliminate the surface imperfections where dangerous contaminates can reside
b. Improved functionality, durability and reliability of medical components
c. Enhanced uniformity and cleanliness of surfaces,
d. Extended component life

2. Elastic Emission Machining (EEM)

A polyurethane sphere is attached to a variable speed motor to set a different rotational speed of
the sphere to maintain a uniform working gap. The sphere is made of polyurethane because of its
elasticity and stability to water. It is manufactured to a surface roughness of about 0.1 µ m or less
by diamond turning, grinding or similar high-precision cutting process
 The size of the abrasive particles is smaller than 1 μm, and they are mixed with ultra-pure
(deionised) water.
 A temperature controller is used to maintain constant temperature during finishing and to
reduce the effect of variable temperatures on the abrasive added liquid medium.
 The workpiece is fixed on a numerical controlled table so that a large area can be finished
by providing raster or circular motion to the workpiece When they contact the workpiece
surface, atom-by-atom material removal takes place, as explained.
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Schematic diagram of EEM machine

Closer view of material removal zone and Atomic interaction between abrasive particle and
workpiece surface.
 It is possible to remove material only when the atoms from both the surfaces create
bonding.
 Binding energy of the topmost layer should be smaller than the binding energy of the
layer below the topmost layer of the workpiece.
 The workpiece surface and abrasive particles are composed of different types of atoms.
So, their interface may be electrically polarised and local charge-up may be induced due
to various states of electrons.
 As a result, atoms of the workpiece located on the top surface are in a different condition
than those of bulk material and it may help in releasing the top atoms during finishing
 Selection of abrasive particles that are chemically active with workpiece material is one
of the most important ways to enhance the MRR
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 The objective of EEM is to remove material atom by atom without inducing any plastic
deformation, cracks, deep indentations. In EEM, abrasive particles have kinetic energy
which they transfer to the workpiece surface and they may cause damage to the
workpiece surface due to their momentum.
 But due to very low mass, they do not aggressively strike the workpiece surface even
though they may have high velocity.
Mechanism of Material Removal
Material removal in EEM depends on the chemical reaction, but it is different from conventional
chemical etching process

Schematic explanation of the interaction between abrasive particles and workpiece surface:
(a) before interaction, (b) hydrogen bonding

(c) dehydration and (d) atom removal

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Surface chemical etching vs. EEM

3. Magnetic Abrasive Finishing (MAF)

 Magnetic abrasives are emerging as important finishing methods for metals and ceramics.
 Magnetic Abrasive Finishing is one such unconventional finishing process developed
recently to produce efficiently and economically good quality finish on the internal and
external surfaces of tubes as well as flat surfaces made of magnetic or non- magnetic
materials
In this process, usually ferromagnetic particles are sintered with fine abrasive particles (Al 2O3,
SiC, CBN or diamond) and such particles are called ferromagnetic abrasive particles (or
magnetic abrasive particles).
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 The magnetic abrasive grains are combined to each other magnetically between magnetic
poles along a line of magnetic force, forming a flexible magnetic abrasive brush.
 MAF uses this magnetic abrasive brush for surface and edge finishing. The magnetic
field retains the powder in the gap, and acts as a binder causing the powder to be pressed
against the surface to be finished.
 Controlling the exciting current of the magnetic coil precisely controls the machining
force of the magnetic abrasives on the work piece

 A special type of adhesive is required for providing a strong bond between magnetic and
abrasive component.
 The amount of adhesive in mixture of abrasive and Ferro magnetic components was
decided completely wets the mixture and at the same time the mixture should not behave
like a fluid.
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4. Magnetorheological Abrasive Flow Finishing (MRAFF)

 Magnetorheological finishing described uses magnetically stiffened ribbon to
deterministically finish optical flats, spheres and aspheres.
 The rheological properties of abrasive laden medium, a new hybrid process termed as
“Magnetorheological Abrasive Flow Finishing (MRAFF).
 This process relies on smart behaviour of magnetorheological fluids whose rheological
properties are controllable by means of external magnetic field.
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 The use of magnetorheological polishing fluid with cerium oxide abrasives for finishing
optical lenses up to the level of 0.8 nm R.M.S. (root mean square) value has already been
demonstrated by MRF process.
 MRAFF process has the capability of finishing complex internal geometries up to
nanometer level
 |Better control on the process performance as compared to AFM process due to in-
process control over abrading medium’s rheological behaviour through magnetic field
 Magnetorheological (MR) fluids, invented by Rabinow in late 1940.
 MR fluids belong to a class of smart controllable materials whose rheological behaviour
can be manipulated externally by the application of some energy fields.
These applications include shock absorbers, damping devices, clutches, brakes, actuators, and
artificial joints
5. Ion Beam Machining (IBM)
 Ion Beam Machining (IBM) is a molecular manufacturing process based on the sputtering
off phenomenon of materials of the workpiece due to bombardment of energized ions of
1 to 10 keV and current density of 1mA/cm2.
 It removes atom or molecules at a time from the surface of the workpiece.
 The Ion beam machining is one of the most precise and fine machining method because
of its basis of action on atomic size stock removal
 The sputtering off is basically a knocking out phenomenon of surface atom of the
workpiece due to the kinetic momentum transfer from incident ions to target atoms.
 Removal of atoms will occur when the actual energy transferred exceeds the usual
binding energy of 5-10 eV
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Schematic illustration of the mechanism of material removal in IBM

Ions of higher energy may transfer enough momentum to more than one atom to cause a
cascading effect in the layers near the surface, removing several atoms. At sufficiently high
energy, cascading events will penetrate more deeply into the solid, several atoms, or molecules
will be ejected out and the bombarding ion will become implanted deep within the material
 Success of ion beam polishing depends crucially on the grain size and initial morphology
of the surface.
 With very small grain size, the machining rate of each grain will be almost the same, and
therefore uniform machining over the surface will take place.
 For large grain size, the difference between the machining rates of the grains results in
the increase in value of surface roughness
 Ion beam machining is ideal process for nano-finishing of high melting point and hard
brittle materials such as ceramics, semiconductors, diamonds etc.
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 As there is no load on the workpiece while finishing, it is suitable for finishing of very
thin objects, optics and soft materials such as CaF2
Group project (Hardcopy and softcopy to be submitted and presented (15%)
A. Write a report on magnetorheological fluids (Materials, properties, applications and
challenges if any)
B. Write a report on Traditional micro/nanofinishing process on different grinding processes
C. Write a report on traditional micro/nanofinishing on Lapping and honing processes
1. Straight Turning of mildsteel rode (G1) by kuba and Behredin)
2. Straight Turing of copper rode (G2) by Abdisa and Mulalem
3. Straight Turning of aluminium rode (G3) by Samson and Robale
4. Flat surface Miling of mild steel (G4) by Redwan and Ayalew
5. Flat surface miling of cast iron (G5) by Assefa and Desalegn
6. Flat surface miling of stainless steel/high alloy steel (G6)
Experiment set up photo
I. Workpiece preparation surface condition (Ra), thickness and composition (test
composition of work piece using EDS)
II. Results and discation
a. Surface finish (use surface profilometer)
b. Chip morphology analysis and c. Tool wear analysis (use imaging)
c. Set machining parameters from literature survey