Optimization to the parameters of abrasive flow machining by Taguchi method

Abstract

This project summarizes the study of the parameters (Number of process cycles, Extrusion pressure and Abrasive concentration) and experimented variation used in Abrasive flow machining (AFM) for the surface finishing process and its optimization using Taguchi method. Abrasive flow machining (AFM) process is a most suitable non-conventional finishing process of internal passages of IC engine vehicles .Workpiece were machined by making all possible arrangements of these parameters on 3 levels which resulted into total of 27 workpiece which were machined to find the optimum value of parameters. Finally the results were verified using Taguchi method to find the optimum value of parameters. It has been found through the experiment that the optimum result is obtained when ‘Number of cycles is equal to 6, Extrusion pressure is 15 bars and Abrasive concentration is 100gm’, which shows that the percentage difference in surface roughness after machining is 26.42%. The result obtained shows that Taguchi designs recognize that not all the factors that causes variability can be controlled. These non-controllable factors are called noise factors. Taguchi designs try to identify controllable factors that can minimize the effects of noise factors.