Experimental Investigation of Process Parameters of Al-SiC-B4C MMCs Finished by a Novel Magnetic Abrasive Flow Machining Setup

Gagandeep  CHAWLA; Vinod Kumar  MITTAL; Sushil  MITTAL

doi:10.48048/wjst.2021.9885

Authors

Gagandeep CHAWLA Department of Mechanical Engineering, NIT, Kurukshetra, Haryana, India https://orcid.org/0000-0002-9458-7222
Vinod Kumar MITTAL Department of Mechanical Engineering, NIT, Kurukshetra, Haryana, India
Sushil MITTAL Department of Mechanical Engineering, Chandigarh University, Gharuan, Punjab, India

DOI:

https://doi.org/10.48048/wjst.2021.9885

Keywords:

MAFM, OVAT, MRR, Al/SiC/B4C-MMCs, ΔRa

Abstract

Abrasive flow machining (AFM) is one of the non-conventional finishing processes used to attain good surface quality and high material removal. However, limited attempts have been made to improve the performance of these processes. This paper presents a novel magnetic abrasive flow machining (MAFM) setup fabricated by adding a magnetization effect in which a nylon fixture and permanent magnets are replaced by a newly fabricated aluminium fixture and coil-type magnets, respectively. Inner cylindrical surfaces of hybrid Al/SiC/B₄C metal matrix composites (MMCs) are finished by the MAFM process. One variable at a time (OVAT) approach is used for studying the effect of 6 input parameters, extrusion pressure (E_p), the number of cycles (N), abrasives concentration (C), workpiece material (W_p), abrasive mesh size (M), and magnetic flux density (M_f) upon response parameters, material removal rate (MRR) and change in surface roughness (ΔRa). The experimental results obtained for MRR and ΔRa show a significant improvement from 3.92 to 7.68 μg/s and 0.49 to 0.74 μm, respectively due to the increase of the extrusion pressure from 1 to 9 Mpa. The MRR and ΔRa was reduced from 6.89 to 6.78 μg/s and 0.46 to 0.22 μm, respectively with an increase in mesh number of abrasives from 80 to 400. The variation in concentration of abrasives from 40 to 60 % shows an improvement in MRR from 4.51 to 6.42 μg/s; whereas, there is a negligible effect on ΔRa which comes out from 3.82 to 3.86 μm. The MMCs, which are used for the experimentation shows a decline in MRR and ΔRa from 5.12 to 3.85 μg/s and 0.77 to 0.42 μm, respectively. This happened because there was a percentage change of reinforcement of SiC from 9 to 7 % and B₄C from 1 to 3 % in Al-6063. An increase in the number of cycles from 50 to 250 shows a significant improvement in both MRR and ΔRa from 1.79 to 3.75 μg/s and 0.97 to 1.86 μm, respectively. Variation in magnetic effect also significantly improves MRR and ΔRa from 1.35 to 3.17 μg/s and 0.38 to 1.06 μm, respectively, when it is varied from 0.15 - 0.45 Tesla. The work carried out shows an overall significant improvement in MRR and ΔRa by using the MAFM process. The MAFM process finds a wide range of applications in finishing like surgical instruments, mechanical components, aerospace industry, electronics industry, etc.

HIGHLIGHTS

The hybrid MMCs (Al/SiC/B₄C) are finished by novel MAFM setup
An aluminium fixture and coil-type magnets play a significant role for finishing the workpiece surfaces
An abrasive laden media acts as a cutting tool in the finishing process
The OVAT approach is used for investigating the parametric effect
The extrusion pressure, number of cycles and magnetic flux density are the significant parameters affecting the MRR and ΔRa

GRAPHICAL ABSTRACT

Downloads

Download data is not yet available.

Metrics

Metrics Loading ...

References

MS Cheema, G Venkatesh and A Dvivedi. Developments in abrasive flow machining: A review on experimental investigations using abrasive flow machining variants and media. Proc. I Mech. Engineers, Part B: J. Eng. Manufact. 2012; 226, 1951-62.

MR Sankar, VK Jain and J Ramkumar. Abrasive flow machining (AFM): An overview. In: Proceedings of the INDO-US Workshop on Smart Machine Tools, Intelligent Machining Systems and Multi-Scale Manufacturing, Indo-US Science and Technology Forum, New Delhi, India. 2008, p. 1-9.

KS Santhosh and SH Somashekhar. A review on abrasive flow machining (AFM). Proc. Technol. 2016; 25, 1297-304.

S Rawangwong, J Chatthong, W Boonchouytan, C Homkhiew, W Cheewawuttipong and R Burapa. Influence of cutting parameters in face milling semi-solid AA 2024 using a carbide tool affecting the surface roughness and tool wear. Walailak J. Sci. Tech. 2017; 14, 441-9.

M Das, VK Jain and PS Ghoshdastidar. Analysis of magnetorheological abrasive flow finishing (MRAFF) process. Int. J. Adv. Manuf. Technol. 2008; 38, 613-21.

S Singh, HS Shan and P Kumar. Parametric optimization of magnetic-field-assisted abrasive flow machining by the taguchi method. Qual. Reliab. Eng. Int. 2002; 18, 273-83.

RS Mamilla, VK Jain and KP Rajurkar. Nano-finishing studies using elastically dominant polymers blend abrasive flow finishing medium. In: Proceedings of the 19th CIRP Conference on Electro Physical and Chemical Machining, Zurich, Switzerland. 2018, p. 529-34.

S Mittal, V Kumar and H Rajurkar. Experimental investigation and optimization of process parameters of Al/SiC MMCs finished by abrasive flow machining. Mater. Manuf. Process. 2015; 30, 902-11.

AD Ghadikolaei and M Vahdati. Experimental study on the effect of finishing parameters on surface roughness in magneto-rheological abrasive flow finishing process. J. Eng. Manufact. 2015; 229, 1517-24.

M Das, VK Jain and PS Ghoshdastidar. Nano-finishing of stainless-steel tubes using rotational magnetorheological abrasive flow finishing process. Mach. Sci. Technol. 2010; 14, 365-89.

SC Jayswal, VK Jain and PM Dixit. Magnetic abrasive finishing process - a parametric analysis. J. Adv. Manuf. Syst. 2005; 4, 131-50.

TC Kanish, P Kuppan, S Narayanan and SD Ashok. A fuzzy logic-based model to predict the improvement in surface roughness in magnetic field assisted abrasive finishing. Procedia Eng. 2014; 97, 1948-56.

L Nagdeve, VK Jain and J Ramkumar. Experimental investigations into nano-finishing of freeform surfaces using negative replica of the knee joint. Procedia CIRP 2016; 42, 793-8.

L Nagdeve, VK Jain and J Ramkumar. On the effect of relative size of magnetic particles and abrasive particles in MR fluid-based finishing process. Mach. Sci. Technol. 2018; 22, 493-506.

R Singh and RS Walia. Hybrid magnetic force assistant abrasive flow machining process study for optimal material removal. Int. J. Appl. Eng. Res. 2012; 7, 2121-4.

R Singh, RS Walia and NM Suri. Study of parametric effect on surface roughness improvement for hybrid centrifugal force assisted abrasive flow machining process. Int. J. Latest Sci. Res. Technol. 2012; 1, 198-201.

N Khatri, S Tewary, V Mishra and RV Sarepaka. An experimental study on the effect of magneto-rheological finishing on diamond turned surfaces. J. Intell. Mater. Syst. Struct. 2013; 1-13.

DC Montgomery. Design and Analysis of Experiments. 5th eds. John Wiley & Sons, New York, 2002, p. 60-119.

RK Jain, VK Jain and PM Dixit. Modeling of material removal and surface roughness in Abrasive flow machining process. Int. J. Mach. Tools Manuf. 1999; 39, 1903-23.

VK Jain, and SG Adsul. Experimental investigations into abrasive flow machining (AFM). Int. J. Mach. Tools Manuf. 2000; 40, 1003-21.

PS Reddy, R Kesavan and BV Ramnath. Investigation of mechanical properties of aluminium 6061-silicon carbide, boron carbide metal matrix composite. Silicon 2017; 10, 495-502.

AK Bodukuri, K Eswaraiah, K Rajendar and V Sampath. Fabrication of Al-SiC-B4C metal matrix composite by powder metallurgy technique and evaluating mechanical properties. Perspect Sci. 2016; 8, 428-31.

HS Shan and S Singh. Development of magneto abrasive flow machining process. Int. J. Mach. Tools Manuf. 2002; 42, 953-59.

AC Wang and SH Weng. Developing the polymer abrasive gels in AFM Process. J. Mater. Process. Technol. 2007; 192-193, 486-90.