Investigation of a novel ultrasonically aided electrochemical magnetic abrasive machining process for SS 316L

Abstract

Many present day applications require machining and finishing of complex-shaped and tough to machine materials with precision and accuracy by conventional or non-conventional machining and polishing processes. Ultrasonically aided electrochemical magnetic abrasive machining (UAEMAM) process is a novel non-conventional machining technique which can machine and finish the product for better surface quality. In present research work, the development and performance evaluation of UAEMAM process for machining of SS 316L is reported. The UAEMAM process is optimised using response surface methodology (RSM) based on central composite design (CCD) and grey relational analysis. The main machining variables of UAEMAM such as work piece rotational speed, working gap, concentration of NaNO3, percentage of abrasives by weight and pulse on time were considered to determine percentage improvement in surface finish (PISF) and material removal rate (MRR). The significant machining factors and the best combination levels of machining parameters associated with PISF and MRR were determined. The present work shows complete elimination of oxide layer from work piece surface, subsequently increasing the PISF value to 84.73 which is 2.73% higher than value achieved by previous studies employed. The benefits of ultrasonic aided electrochemical magnetic abrasive machining were also confirmed from the micrograph observations of the surface. Experimental results show that UAEMAM process is effective for machining and polishing components for better surface finish.