It is the of Advancement of Abrasive Flow Machining, Which is used for the Deburring,Surface Finishing,Removing the Recast Layer.

1. A
Seminar
on
Magneto-Abrasive Flow Machining
submitted in partial fulfillment of the requirements for the award of the
Degree of
Bachelor of Technology
in
Mechanical Engineering
By
Akash U. Nagargoje
(Roll No. 20170174)
under the guidance of
Dr. V. G. Sargade
DR. BABASAHEB AMBEDKAR TECHNOLOGICAL
UNIVERSITY,LONERE.
November 2019

2. Outline of the Presentation
 Introduction
 Process details
 Classification
 Process parameters
 Advantages
 Limitations
 Applications
 Comparison between AFM and MAFM
 Conclusion
 References

3. INTRODUCTION

4.  What is MAFM?
 It is non-conventional machining process which has been
successfully employed for the high level surface finishing, for
removing the recast layers of precision products and also for
deburring.
 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,
modelling of surface generation and process monitoring of AFM
was conducted by Williams and Rajurkar during the late 1980s.
 Study on Development of magneto abrasive flow machining process
by Sehijpal Singh, H.S. Shan in 2002.

5.  PRINCIPLE
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,
which results in micro-chipping, surface finishing.

6. a) Off-state MR fluid particles (b) Aligning in an applied magnetic field
Fig. Principle of Material Removal Mechanism

7. PROCESS DETAILS

8.  MAFM Set-up
1) Cylinder containing
medium
2) Flange
3) Nylon fixture
4) Workpiece
5) Eye bolt
6) Hydraulic press
7) Auxiliary cylinder
8) Modular relief valve
9) Piston of Hydraulic press
10) Directional control valve
11) Manifold blocks
12) Manifold Blocks
13) Electromagnet

9. ► 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
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
It is the mixture 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

10. CLASSIFICATION

11. TYPES OF MACHINES
 One-way machine:
medium chamber adapted to receive
and extrude medium unidirectionally
across the internal surfaces of a work
piece

12. 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 passage way through or past
the work piece surface to be abraded.
Two-way machines:

13. Orbital Machines:
While finishing
In orbital MAFM, the work piece is
precisely oscillated in two or three
dimensions
Before start of finishing
Orbital MAFM Process
When work piece with complex
geometry translates, it
compressively displaces and
tangentially slides across the
compressed elastic plastic self-
formed pad result in surface finish.

14. PROCESS PARAMETERS
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.

15.  EFFECTS OF PARAMETERS
`S

16.  ADVANTAGES
 A very high volume of internal deburring is possible.
 MAFM deburrs precision gears.
 MAFM polishes internal and external features of various
components.
 MAFM removes recast layer from components.
 Effective on all metallic materials.
 Controllability, repeatability and cost effectiveness.
 Less Time Consumption as compare to AFM

17.  LIMITATIONS
 Abrasive materials tend to get embedded, if the work
material is ductile.
 Require closed environment.
 Mostly magnetic materials.

18.  APPLICATIONS
 Automotives
 Medical implants
Fig. Helical gear before and after finish
Fig. Medical implants

19. ► Manufacturing industries
Fig. Turbine blades before and
after finishing.
Fig. Knee joint before and after finishing

20.  COMPARISON BETWEEN AFM
AND MAFM
S. No. Extrusion
Pressure
(psi)
No. of
Working
Cycles
PISF %
(AFM)
PISF %
(MAFM)
1 700 5 10.8 12.3
2 700 15 19.8 22.11
3 700 25 28.3 29.5
4 700 35 32.4 34.4
5 700 45 37.1 38.4
6 700 55 39.1 40.3
Table. 4.1 Effect of No. of cycles on PISF on extrusion pressure 700 psi

21. S. No. Extrusion
Pressure (psi)
No. of
Working
Cycles
PISF %
(AFM)
PISF %
(MAFM)
1 900 5 19.2 22.7
2 900 15 23.1 26.5
3 900 25 34.1 40.3
4 900 35 40.2 43.6
5 900 45 43.1 46.1
6 900 55 43.8 46.9
Table. 4.2 Effect of No. of cycles on PISF on extrusion pressure 900 psi

22.  CONCLUSION
 Magnetic field significantly affects both MR. The slope of the
curve indicates that MR increases with magnetic field.
Therefore, more improvement in MR is expected at still
higher values of magnetic field.
 Magnetic field and medium flow rate interact with each other.
The combination of low flow rates and high magnetic flux
density yields more MR.
 Medium flow rate does not have a significant effect on MR
and ΔRa in the presence of a magnetic field.
 MR and ΔRa both level off after a certain number of cycles.

23. REFERENCES

24. REFERENCES
 L.J. Rhoades, Abrasive flow machining and its use, in: Proceedings
of Non Traditional Machining Conference, Cincinnati, OH,
December, 1985, pp. 111–120.
 V.K. Jain, R.K. Jain, Modelling of material removal and surface
roughness in abrasive flow machining process, Int. J. Mach. Tool
Manuf. 39 (1999) 1903–1923.
 A.B. Khairy, Aspects of surface and edge finish by magneto abrasive
particles, in: Proceedings of International Conference on Advanced
Manufacturing Technology, Malaysia, August 2000, pp. 77–84.
 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.
 J.H. Neilson, A. Gilchrist, Erosion by stream of solid particles, Wear
11 (1968) 111–122.
 T. Shinmura, H. Yamaguchi, Study on a new internal finishing
process by the application of magnetic abrasive machining, JSME
Int. J., Ser. C 38 (4) (1995) 798–804.

25.  Rhoades LJ, Kohut TA and Nokovich NP. Unidirectional abrasive
flow machining. Patent number 5367833,USA, 29 November
1994.
 Rhoades LJ and Kohut TA. Reversible unidirectional AFM. Patent
number 5,070,652, USA, 10 December 1991.
 Gilmore JR and Rhoades LJ. Abrasive polishing method, apparatus
and composition. Patent number 6,273,787, USA, 14 August 2001.
 R.E. Williams, K.P. Rajurkar, Performance characteristics of abrasive
flow machining in: SME Paper FC89-806, Society of Manufacturing
Engineers, Dearborn, MI, USA, 1989, pp. 898–906.
 Palwinder Singh, Research Scholar, IKGPTU Jalandhar, Punjab,
India, Experimental Comparison of Abrasive Flow Machining and
Magnetic Abrasive Flow Machining for Aluminum Tubes
International Journal for Research in Engineering Application &
Management (IJREAM) ISSN : 2454-9150 Vol-04, Issue-03, June
2018
 Wang A.C., Weng S. H., “Developing the polymer abrasive gels in

26. THANK YOU