ON THE PERFORMANCE ANALYSIS OF FLEXIBLE MAGNETIC ABRASIVE BRUSH

ABSTRACT

Magnetic abrasive finishing (MAF) of alloy steel workpiece with unbounded magnetic abrasive particles (UMAPs) indicates that the surface finish in the range of nanometer can be achieved. Important controllable four process parameters have been identified which are as current to the electromagnet, machining gap, abrasive size (mesh number), and number of cycles. Experiments have been planned using design of experiments technique. Based upon the results of response surface methodology and analysis of variance (ANOVA), it is concluded that magnetic flux density that depends on current to the electromagnet and machining gap, is most influencing parameter followed by grain size and number of cycles. The surface roughness profile generated during the MAF process has been discussed. To understand the cutting mechanism of magnetic abrasive finishing process, scanning electron microscopy (SEM) and atomic force microscopy (AFM) of the machined surfaces have been carried out. The correlation between surface finish and material removal has also been established.

Keywords:

• MAF
• Design of experiments
• FMAB
• Nanofinish

ACKNOWLEDGMENT

The authors acknowledge the financial support of The Department of Science and Technology, Government of India, New Delhi, for the project on “Investigations into Magnetic Abrasive Finishing (MAF) of Plane Surfaces.” The suggestions of Prof. M. Sachchidanand, Electrical Engr. Dept., I.I.T. Kanpur are acknowledged with thanks. Mr. Dinesh Deva, and Mr. Kisun K. Saren, Indian Institute of Technology Kanpur have helped in carrying out the analysis of the work.

Notes

X₁ = Current (A)

X₂ = Machining gap (mm)

X₃ = Grain mesh number

X₄ = Feed (mm/min)

MR = Material Removal

Δ Ra = Reduction in surface roughness value (CLA).

*Significance at 95% confidence interval.

On deputation from M.M.M. Engineering College, Gorakhpur 273010 (UP), India.