Design and Development of Hybrid Electrochemical and Centrifugal Force Assisted Abrasive Flow Machining

Abstract

Abrasive flow machining is a nontraditional polishing process to polish metallic components using a semi-liquid paste, and with which complicated or miniaturized parts requiring high surface finish can be economically produced. To explore the possibility of a novel way of integrating AFM with electro-chemical machining with the objective to enhance its efficiency and quality of finish surface this study was undertaken. The newly design and developed solution is formed as electrochemical and centrifugal force assisted abrasive flow machining process (EC2A2FM)for various range of parameters. The effects of EC2A2FM process parameters, such as, Voltage, Salt molal concentration, RPM etc.and constant parameter such as number of cycles, extrusion pressure on material removal have been investigated. Taguchi method based experimental design was applied to optimize the hybrid AFM process parameter for better material removal. Analysis of variance (ANOVA)was applied to identify the significant parameters for maximum material removal. The analysis of results showed that there was enhanced material removal in EC2A2FM as compared to the other hybrid AFM process, as well as the operating pressure was allows 6N/mm2. This small operating extrusion pressure was very much important as far as fragile components has to prevent from damageand retain their geometrical tolerances,this seems to be the contributing factor for the increase in material removal and % improvement in surface roughness.