Experimental investigations into ultrasonic assisted magnetic abrasive flow machining process

ABSTRACT

In the present study, an advanced variant of abrasive flow machining (AFM) is developed. Ultrasonic assistance and magnetic field assistance with rotating effect have been designed, fabricated, and simultaneously used to develop ultrasonic-assisted magnetic abrasive flow machining (UAMAFM) process. The ultrasonic horn and electromagnets were designed based on the simu modified by adding iron particles to make abrasive media respond effectively under the applied magnetic field. The effects of the external assistances, machine, and media-based parameters were explored on the amount of material removed (MR) and percentage improvement in the surface roughness (% ΔR_a) for pure titanium (Grade II). The influence of input parameters was investigated using analysis of variance (ANOVA) by analyzing the process responses. Quadratic regression models showing the effect of input parameters and their interaction were developed for each response. The influence of individual parameters on process outcomes and response surface plots for significant interactions have also been discussed. The maximum MR of 26.62 mg and ΔR_a of 54.42% were achieved at the optimized setting of process parameters. The predicted values of MR and % ΔR_a from developed statistical models agreed with the experimental results.

KEYWORDS:

• Abrasive
• flow
• machining
• ultrasonic
• magnetic
• optimization
• media
• statistical
• models

Acknowledgement

The authors would like to acknowledge UCOST, Dehradun (UST-1380-MID) and FIG, IIT Roorkee (MID/FIG/100797) for funding this research work.

Disclosure statement

No potential conflict of interest was reported by the author(s).

Additional information

Funding

The work was supported by the Indian Institute of Technology Roorkee [MID/FIG/100797]; Uttarakhand State Council for Science and Technology [UST-1380-MID]