“MAGNETIC ABRASIVE FINISHING MACHINE”

A PROJECT REPORT

Submitted by
IMRAN MASTER(21619SBEME30128)

RAJAN DESAI(21619SBEME30148)

HARSH PATEL(21619SBEME30139)

NEEL PRAJAPATI(1519BEME30103)

In fulfilment for the award of the degree

of
BACHELOR OF ENGINEERING
in
MECHANICAL

LDRP Institute of Technology and Research, Gandhinagar

Kadi SarvaVishwavidyalaya, Gandhinagar
OCTOBER-NOVEMBER 2017
 LDRP INSTITUTE OF TECHNOLOGY AND RESEARCH
GANDHINAGAR

MECHANICAL Engineering Department

CERTIFICATE
This is to certify that the Project Work entitled “MAGNETIC ABRASIVE
FINISHING MACHINE” has been carried out by IMRAN MASTER
(21619SBEME30128) under my guidance in fulfilment of the degree of Bachelor
of Engineering in MECHANICAL (5th Semester) of Kadi Sarva Vishwavidyalaya
University, Gandhinagar during the academic year 2017-18.

Mr. V.D.PATEL PROF. D.H.PANDYA

Internal Guide Head of the Department

LDRP-ITR LDRP-ITR

External Guide
 ACKNOWLEDGEMENT

First and foremost, I wish to express my sincere appreciation to my project guide

Mr.V.D.PATEL SIR for constantly guiding and encouraging me throughout this
study. Without her support and interest, this project would not have been the same
as presented here. I am very grateful to her for her patience and her constructive
comments that enriched this project.

I express my sincere gratitude to the review committee headed by Prof

D.H.PANDYA and all other professors of Mechanical Engineering department,
LDRP-ITR.

My acknowledgement also extends to all my classmates and others who have

provided assistance and guidance to me at various occasions directly or indirectly.
Their views and tips are useful indeed.

Date:

Place:

IMRAN MASTER(21619SBEME30128)

RAJAN DESAI(21619SBEME30148)

HARSH PATEL(21619SBEME30139)

NEEL PRAJAPATI(21619SBEME30128)

LDRP-ITR
 ABSTRACT

Study of new and cost effective finishing processes has always been an area
of keen interest to overcome the difficulties of existing finishing process. Magnetic
Abrasive Finishing(MAF) is a process in which a mixture of non-ferromagnetic
abrasives and ferromagnetic iron particles is used to do finishing operation with the
aid of magnetic force. The iron particles in the mixture are magnetically energized
using a magnetic field. The iron particles form a lightly rigid matrix in which the
abrasives are trapped. This is called Flexible Magnetic Abrasive Brush(FMAB),
which when given relative motion against a metal surface, polishes that surface.

The major studies concerning MAF have been done regarding the behaviors of
the process under the effect of various parameters like working gap, mesh number
of abrasive, speed of relative motion on cylindrical and flat work-pieces taking one
type of material, non-ferromagnetic or ferromagnetic only. But limited
comparative study by taking stainless steel with ferromagnetic behavior has been
done to analyze the surface roughness that is generated during the process.

This Magnetic abrasive surface finishing tool is used for removing burs, scratches
Scaling, occurs in the grinding and drilling process. It is the mircro deburring
process, and hence it development over the grinding process. With use of magnetic
field around the work piece in we can increase the material removal rate as well as
the surface finish.

In case of ferromagnetic work-piece, percent composition of iron powder has more

effect than the other parameters. With increase in mesh size of abrasive, percent
improvement in surface roughness increases. With increase in current the percent
improvement in surface roughness value increases much more than the other
parameters, therefore effect of applied current is seen to the most significant
amongst all the parameters.
 TABLE OF CONTENTS

Acknowledgement

Abstract

List of figures

Table of content

Chapter: 1: INTRODUCTION

Chapter: 2: LITERATURE REVIEW

Chapter: 3: WORKING PRINCIPLE

Chapter: 4: MATERIAL USED IN MASF MACHINE TOOL

Chapter:5: OPERATON USED FOR MANUFACTURING PARTS & MACHINE USED

Chapter:6: MACHINE SETUP

Chapter:7: WORKING PROCEDURE ON MACHINE

Chapter:8: ADVANTAGES

Chapter:9: APPLICATION

Chapter:10: FUTURE SCOPE

References
CHAPTER:-1 INTRODUCTION

A magnetic abrasive finishing process is defined as a process by which material is

removed, in such a way that the surface finishing and deburring is performed with
the presence of a magnetic field in the machining zone. Magnetic abrasive
finishing (MAF) has a magnetic field which assisted finishing process. The work
piece is kept between the two poles of a magnet. The method was originally
introduced in the Soviet Union, with further fundamental research in various
countries including Japan. Nowadays, the study of the magnetic field assisting
finishing processes are being conducted at industrial levels around the world.
Figure No.1
Magnetic abrasive are emerging as important finishing methods for metals and
ceramics. Magnetic abrasive finishing is one such unconventional finishing process
developed recently to produce efficiently and economically good quality finish on
the internal and external surface of tubes as well as flat surfaces made of magnetic
or non-magnetic material. In this process, usually ferromagnetic particles are
homogenously mixed with fine abrasive particles. Fig shows a plane magnetic
abrasive flow process in which finishing action is generated by the application of
magnetic field across the gap between workpiece surface and rotating
electromagnet. The enlarge view of finishing zone in fig. show the force acting on
work surface to remove material form of chips. Force due to magnetic field is
responsible for normal force causing abrasive penetration inside the workpiece
while rotation of the magnetic abrasive brush results in material removal in the
form of chips.

The magnetic abrasive grains are combined to each other magnetically between
magnetic poles along a line of magnetic force, forming a flexible magnetic
abrasive brush. Magnetic abrasive flow uses this magnetic abrasive brush for
surface and edge finishing. The magnetic field retains the powder in the gap, acts
as a binder causing the powder to be pressed against the surface to be finished. 3D
minute and intricately curved shape can also be finished along its uneven surface.
Controlling the excited current of the magnetic coil precisely controls the
machining force of the magnetic abrasives on the workpiece.

Since the magnitude of machining force caused by the magnetic field is very low
but controllable, a mirror like surface finish is obtained.
CHAPTER:-2 LITERATURE REVIEW

Change in the strength of magnetic field in the direction of the line of magnetic for
center the work-piece surface will actuate the magnetic abrasive particle. The
effective way of changing the force/finishing pressure and rigidity of MAFB is
through the change in diameter “D” of magnetic abrasive particle. Hence,
ferromagnetic particles of several times the diameter of diamond abrasive “d” are
mixed to form the magnetic abrasive brush. MAF is affected by the material, shape
and size of the work-piece, and shape and size of the magnetic pole. Pressure
increases with increase in flux density and decreases as the clearance gap between
tool &work-piece increases. Larger the particle size, poorer the finishing (except
for 50µm particles) but higher is the stock removal which increases linearly
with finishing time.

The surface roughness is predicted as a function of finishing time by a model that

has been derived from the removed volume of material. Thus, it is possible, from
the surface-roughness model, to predict the time when existing scratches are
completely removed.The magnetic force acting on the magnetic abrasive,
controlled by the field at the finishing area, is considered the primary influence on
the abrasive behavior against the inner surface of the work-piece .

With increase in working gap, the percentage improvement in surface roughness

increases initially, reaches a maximum value and then it starts decreasing [4].
Removal of burrs in large surfaces with drilled holes using MAF shown that this
method can be applied both for ferromagnetic and non-magnetic parts. This
method can be improved as applied to new tasks of deburring.

The finishing characteristics of unbounded magnetic abrasive within cylindrical

magnetic abrasive finishing: The unbounded magnetic abrasive is a mechanical
mixture of SiC-abrasive and ferromagnetic particles with a SAE30 lubricant. Iron
grit and steel grit, three particle sizes were prepared for both and were used as
ferromagnetic particles, each of them being mixed with 1.2 and 5.5 µm SiC
abrasive, respectively. Results indicate that steel grit is more
Suitable for magnetic abrasive finishing because of its superior hardness and the
polyhedron shape. However its corrosive resistibility decreased on a surface that
was finished via steel grit mixed with Sic abrasive. Important parameters
influencing the surface quality generated during the MFA were identify as: (i)
Voltage (DC) applied to the electromagnet , (ii) Working gap , (iii) rotational speed
of the magnet , and (iv) abrasive size (Mesh number).

Efficient finishing of magnesium alloy is possible by the process. The volume

removed per unit time of magnesium alloy is larger than that of other material such
as brass and stainless, that is, high-efficiency finishing could be achived. Micro-
burr of magnesium alloy could be remove easily in short time by the use of MFA.

MFA process creates micro scratches having width less then 0.5 μm on the finished
surface. Moreover, the surface. have finished by the shearing of the peaks
resulting in circular lays formed by the ro1lltion of the FMAB. It shows that the
finished surface bas fine scratches/micro-cuts which arc farther distant apart
resulting in smoothened surface. But these fine scratches would also disappear
by using higher mc. h number (finer abrasive particles).

A new technique was developed to compare the performance of the magnetic

abrasive powders and to find the powder that is appropriate for finishing and
deburring of drilled holes placed on a plane steel surface. Proper deburring
conditions are suggested to satisfy the productivity and the accuracy f J O]. In
addition to deburring, efficiency influence to surface roughness is analyzed. To
improve the surface roughness and purity, volume of powder, height of gap,
inductor rotational frequency, feed velocity and the method of coolant supply
arc analyzed and proved that the continuous flow of coolant and the Fe powder
without abrasive ineffective for deburring and surface quality
CHAPTER:-3 WORKING PRINCIPLE
The working gap between the work piece and the magnet is filled with magnetic
Abrasive particles (MAP}, composed of ferromagnetic particles and abrasive
powder. MAP abrasive particles join each other along the lines of magnetic
force and form a flexible magnetic abrasive brush (FMAB) between the work
piece and the magnetic pole. This brush behaves like a muhi-point cutting tool
for finishing operation . When the magnetic N-pole is rotating, the Magnetic
Abrasive Finishing Brush (MAFB) also rouues like a flexible grinding wheel
and finishing idone according to the forces acting on the abrasive particles.

In external finishing of cylindrical surface, the cylindrical work piece rotates

between the magnetic poles, with the MAP filled in both the gaps on either side
whereas in internal finishing of cylindrical surface, the work piece rotates
between the magnetic poles and the MAP as shown .The magnetic field
generator can be either electromagnetic coils or permanent magnets. The
relative motion between the induced abrasive particles of the FMAB and work
piece generates the necessary shearing action at the abrasive-work-piece
interface Lo remove material from the work-piece in the form of miniature
chips.
CHAPTER:-4 MATERIAL USED IN MAGNETIC ABRASIVE
SURFACE FINISHING MACHINE TOOL.
SHELL OF ELECTROMAG NET -

EN-19

Carbon 0.35-0.45

Manganese 0.50-0.80

Silicon 0.10-0.35

Sulphur 0.40

Phosphorus 0.40

Chromium 0.90- 1.40 Nickel -

Magnesium 0.20-0.40

It includes. l% chromium molybdenum high tensile steel and is suitable for

highly stressed application where greater strength is required. It is a soft
magnetic material .

SPINDLE SHAFT -

STAINLESS STEEL- Austenitic steels

Type AISJ (American Iron and Steel institute) 201

C (max) 0.15

Mn (max) 5-7

Si (max) 1

Cr 6-18

Ni 3.5-5.5

Others 0.25N max

It is non-magnetic material
FIXTURE -

Aluminum

SLIP-RI G -

Copper Epoxy plastic

WIRE FOR WINDING

Copper Carbon bush

GRAIN OF IRON-

1. EN-31

C0.90- 1.20

MN 0.30-0.75

Si 0.10-0.35 S0.40

P 0.40 Crl.00- 1.60

ii. Stainless s1ecl SUS 4JOL -

A Ferrite stainless st eel with corrosion resistance.

Fe- 3% Si- high flux density, high frequency and low coactivity.

Fe-Ni- will high magnetic permeability, high magne1ic flux density, high
resistance, low frequency and low coactivity.

HOLDER FOR CARBON BUSH AND CONNECTION FOR SLIP RING-

Copper
WORK PIECE -

Stainless steel-AUSTENITE

Type AISI (American Iron and Steel institute) 201 C (max) 0.15

Mn (max) 5-7 Si (max) I

Cr 6-18

Ni 3.5-5.5

Others 0.25N max

It is non -magnetic material

ABRASIVE GRAIN - ALUMINIUM OXIDE -

Purpose -Abrasive grade

Specification -JOO Grain size

Chemical composition (%)

AL2O3 min -94

Sio2 max

Ti02 max

Magnetic material content (0.03%)

Aluminum m oxide (AL2O3) - This abrasive carried very hard and tough
grains having sharp cutting edges. It is obtained by fusing the impure
aluminum oxide called Bauxite, in an electric arc furnace. For this, the dry
bauxite in is mixed with ground coke and iron chips. This mixture is charged
into the furnace and a heavy current passed through it. The mass fuses on
account of the excessive heat generated in the furnace and a black of
aluminum oxide is formed. The iron scrap acts as a flux; collect up the block
of aluminum oxide is formed . The iron scrap acts as a flux, collect up the
impurity and settles at the bottom of the furnace. As soon as the block is
formed, the furnace the furn ace is switched off and allowed to cool slowly.
When the temperature goes down sufficiently, the block is removed from
the furnace. It is t h e n crushed and the powdered grain, thus formed,
screened through standard meshes. These grains arc not a hard as those of
silicon carbide but, on account of being less brittle than the latter, are preferred
for grinding metals of high t ensile s1rength. The common trade names for this
abrasive are 'Alundum ', 'Alum inum Oxide', 'Aloxit' and 'Borolon.

TOOL SIGNATURE

110*5*0 SW A 100 ELM MAG

TOOL DIA = 110mm

THICKNESS OF ABRASIVE LAYER =5
BORE OIA= O

ELECTROMAGNETIC FORCE

SW -MANUFACTURE PREFIX TO ABRASIVE.

A -ABRASIVE ALUMINIUM OXIDE (AL203)
100- GRAIN SIZE
F-IT JS GAIN FINE GRADE
100-FREE PARTICLE
ELM-ELECTROMAGNETIC FORCE
MAG= MAGNETIC FORCE
CHAPTER:-5 OPERATION USED FOR MANUFACTURING
THE PARTS &MACHINE USED.

LATHE MACHINE -
The lathe can be defined as a machine tool which holds the work between
rigid and strong supports, called centers, or in a chuck or face plate while the
latter revolves. The chuck or the face plate is moun ted on the project end of the
machine spindle. The cutting tool is rigidly held and supported in a tool post and
is fed against the revolving work. While the work revolves about its own axis
the tool is made to move either parallel to or at an inclination with this axis to
cut the desired material . In doing so it produces a cylindrical surface, i f it is fed
parallel to the axis, or will produced a tapered surface if it is fed at an
inclination.

OPERATION DONE ON LATHE –

1) TURNING BETWEEN CENTRES -

When the work is held between centers for any sort of turning operation,
one end is firmly gripped in a lathe dog and then the same end is support ed on
the tip of the live Centre. Tail of the dog engages with the driving plate and the
other end of the job is supported on the dead center fitted in the tail stock.Work
revolves durin g the operation and the tool is fed against the job.
Enough care should be taken while staring the operation, particularly by a
beginner. Speed of spindle and its direction of rotation should be checked and
suitably adjusted. Rough cuts in the beginning should be depth of cut reduced.
Check the controls and practice hand feeds which, in due course, can be
followed by power feeds. For taking any sort of measuremen t always stop the
machine.

2) TAPERTURNING -
A large variety of components used in engineering practice is found to have
conical shapes or, if flat, having a gradual reduction in its width or thickness
along their length. Such components arc known as tapered . For conical
pieces, the difference between the diameters of their ends is known as taper
and for fall pieces the difference between the widths of thickness is known as
taper.
The common methods expressing taper -
Taper I in X ; for this, the units should be uniform, such as taper I in 20 means
whether a taper of I inch on 20 inches length or a taper of I foot over 20 feet length
of the job.
In metric units we usually express the taper in 1in x form, all measurements being
in millimeters.

Metric taper -
It provides large range of taper suitable for different types of components used in
engineering practice. Usually eight sizes of metric taper are used and these
prevalent sizes are designated by different number 4, 6, 80, J OO, 120, 140, 160,
and 200. The number of taper indicates the size of larger diameter in millimeters.

The total taper on the job is given by:

Total taper = (D-d)/L

It is usually expressed, as stated above as taper per unit length of the job
Taper = (D-d)/L

METHOD OFTAPER TURNING -

Various methods arc used for turning taper on a job. The most common of this arc
the following.

I. Tail stock set-over method.

2. By swiveling the compound rest.

TURNING TAPER BY SWIVELING THE COMPOUND REST-

Steep and short external taper can easily be turned in a lathe by swiveling the
compound rest on the carriage through an angle tan a, which is equal to half the
total included angle of the taper.
3) SCREW CUTT ING ON LATHE -

Screw culling is a very interesting and commonly performed operation on a lathe. It

calls for a fairly high skill on the part of the operator. It is evident, therefore, that this
process should be very carefully understood. Before we actually take up this operation
practically on the lathe it is necessary that we should be fully conversant with the
different types of threads used in engineering practice, their detailed specification
and use, various term used in relation in them, their shapes and similar other relevant
detail such details can be obtained from any standard book.

4) PROV IDING UNDERCUT -

Undercuts are very necessary when cutting threads on stepped work. When job has
two di fferent diameter and threads arc to be cut on smaller diameter, it is essential to
provide an undercut where the two steps meet . It allows for the overrun of the tool
after one cut is over. In the absence of this undercut there is always a like hood of
the tool running into the larger diameter after finishing the cut. This will lead the tool
to dig, which may result in either riding of job over the tool, bending of job,
breaking of job or breaking of tool. As far a. possible, the undercut should be wide
enough to allow sufficient time to the operator to disengage the half nut and withdraw
the tool after finishing the cut. Its depth should always be slightly more than the
dcp1h of the thread .

5) DRILLING ON LATHE -

It is an operation which very frequently prefunded on lathes. Jobs, which gave a short
length, very quickly drilled on lathe. For this operation, the work is held in a
suitable device, such as chuck or face plate, usual, and the drill is held in the sleeve
or barrel of the tail stock.Dead center is removed and either a drill chuck or sleeve is
inserted in it. Place. Straight shank drills are held in drill chucks whereas the taper
shank drill arc held in sleeves. The outer surface of the sleeves or the shank of the drill
chuck carries a taper corresponding to tapered hole of the barrel of the tail stock it is
checked whether the drill point is concentric with the center of the hole to be drilled
or not. If eccentricity, it is removed.Then, the drill is fed by hand by rotating the hand
wheel of the tail stock. In ca c of blind holes, the required depth is measured and
marked on the drill. If the tail stock barrel carries graduated scale it is used for
selling the required axial advancement of the drill.
6) BORING ON LATHE-

It is an operation which is employed for machining internal surfaces. In this

sense, it can be termed a internal turning. Holes produced by ca. ting, forging, and
sometimes drilling also required subsequent machining to enlarge them and bring
them to the exact required size. The operation of boring involves enlarging of holes
through machining.

CUTTING TOOL MATERIALS -

HIGH SPEED TOOL STEELS -

These steels maintain high hardness up to a temperature of about 550"c and hence
can be used for cutting of metals at high speeds. They also have high wear
resistance and culling ability.

DESIGN CONSIDERATIONS

Electromagnet
Magnetic field
Shaft
Slip Ring
Work piece fixture

A. ELECTROMAGNET

The shape of electromagnet is round with internal hollow that almost

completely encloses the coil. The design of electromagnet has a shielding effect
which reduces electromagnetic interference.

The material of shell of electromagnet is soft magnetic material because magnetic

material , which are easily magnetized and demagnetized are known as soft
magnetic material.
B. MAGNETIC FIELD -

The area around a magnetic pole or a magnetic pole or a magnet within which its
influence is perceptible is, is called its magnetic field. The spaces around d a
compass needle, around d the earth, and around a permanent magnet, are examples
of magnetic fields.
Such continuous curves a magnetic field are normally termed as magnetic lines of
force. These lines of force travel from the north to the South Pole. This arc
assumed to continue though the magnet to the point from which they have
emerged.

MAGNETIC FLUX (Φ) -

The total number of lines of force comprising the magnetic field is called the
magnetic flux. In SI unit system unit North Pole i.e. North Pole of strength of one
Weber is supposed to radiate out the flux of one Weber.
The lines of magnetic flux have no physical existence; nothing flows in a magnetic
field. The concept of these lines is purely imaginary.

FIELD STRENGTH -

A Jong conductor is wound with number of turns close together to form a coil
whose axial length is several times greater than the diameter of its turns.
Let the magnetic field strength along the axis of the solenoid be H. let us assume
that the value of H remains constant throughout the length of the solenoid. The
ampere turns linked with this path of N1 where N is the number of turns of the
solenoid and I the current in amper passing through it, According to ampere's
work law.
H= Magnetic field strength N/Wb (or A/mm)
B= Magnetic flux density Wbtm'
N= Number of turns = 50
µo= Absolute permeability
µr = Relative permeability
l = Length of solenoid 45mm
Current I = 1A
Hxl=Nxl

OR H = NI/l

B = µr µo (NI/l)[Wb/mm2]------------- For a medium

= µo (NI/l)[Wb/mm2]

B= (4π*10^-7*450*50*5)/45
= 0.003141592 (Wb/mm2 or T]

MAGNETO MOTIVE FORCE -

In an electric circuit, the current is due to the existence of an electromotive force.

By analogy, we my say that in an magnetic circuit the magnetic flux is due to the
existence of a magneto motive force (M.M.F) caused by a current flowing through
one or more tum . In sort, drives or tend 10 drive fluxes through magnetic circuit.
The value of M.M.F is directly proportional to product of current (I) & number of
turns (N).

M.M.F = N.l Ampere-turns or amperes.

It is descriptively expressed in ampere turns, but N being a dimensionless unit for

MMF is an ampere, and an ampere of m.m.f is quite different from the current
ampere.

M.M.F. also defined as the work done in joules in carrying a unit magnetic pole
once through the entire magnetic circuit.

Total M.M.F = NI
=50*5
= 250 AT
Material selection criteria -

 When shell of electromagnet is manufacturing it require soft material

hence we select EN-I9 material.
 Putting properties of well electromagnet we select soft magnetic material
which easily magnetize and demagnetize.

Result -

Using above result i.e. shape of electromagnet, and magnetic field strength
generated in electromagnet. Its external diameter is designed according to
dimension of work piece.
C.SHAFT -

1) Shaft consist of three portion used for giving attachment

 For Radial drilling machine sleeve i.e. taper portion.

 For Shell of Electromagnet, threading and tapping is created at opposite end
of shaft.

A .Taper portion

In metric units we usually express the taper in 1 in x form, all measurement

being in millimeters.

The total taper on the job is given by:

Total taper = D-d, L is the total length of tape

It is usually expressed, as stated above as taper per unit length of the job

Taper = (D-d)/L

= 24-20/96

= 4/96

=1/24

Taper is given by 1:24.

B. For threading

We used standard thread M30x2

Root diameter- 27.84mm

External diameter -30mm

Pitch -2

Thread length -30mm flat face

V-type thread
C. For Tapping

We used standard according to M30x2

Root diameter -27.84mm

Outer diameter -30mm

Pitch -2

Hole depth -30mm

V-type bottom angle is 120°

V- Type thread

D. Diameter of Shaft Mechanical properties of stainless steel austenite -

Proof stress = 310 N/mm 2

Tensile strength = 665 N/mm2

Elongation = 40 %

3.0 hp = 2.206 KW

Power = 2.206 X10^3 W

Rotation per minute N= 1440 r.p.m.

T= px60/ (2πxN)

T= (2.206 x 10^3 x 60) / (2π x 1440)

T = 14.6289 N -m

T = 14.6289 x 103 N - mm

T= Twisting moment (or torque) acting upon the shaft.

J= polar moment of inertia of the shaft about the axis of rotation.

D. SLIP RING -

 Operating speed rpm - 1440 rpm

 Circuit .signal rings (Circuit, ring and way arc all synonymous. If there is a
return path or ground then it is a separate circuit. In some slip rings a circuit
can be used either way and is counted only once.)
 Maximum voltage and current for the power circuits and signal circuits.-220
V, 3K\V
 Type of signal (very important) -DC signals
 Operating temperature - 100.c
 IP grade (sealing requirements)

Result

Select slip ring which is available in market and suitable for above consideration
point. Outer diameter does not matter becau.se a lot of space is available for
rotation.
E. FIXTURE -

A fixture does more or less the same work as a jig in that it bold and locates the
successive work pieces in identical position, but differs from a jig in that it does
not guide and locate the tool. The tool bas to be adjusted separately. A fixture is
usually of a massive and heavier construction than jig and fixed or bolted to the
table of the machine to ensure proper rigidity.

EXTERNAL PIN LOCATION

This type of location technique employs the use of pins externally along the profile
of an odd shaped component. Many a times, such requirement occurs in machining
of jobs having irregular shapes and also in fabrication work, such as of framed
structures. For this, the exact profile of the surface of base of the jig or fixture. Pins
arc then arranged on all key points along the marked profile.

Result

Work piece is flat stainless steel and hence for easy handling i.e. inserting and
removing from fixture, select external pin locator.
CHAPTER:-6 MACHINE SET-UP
Fundamental requirement of the experimental set-up are:

A. Magnetization unit

B. Magnet rotary motion unit

C. Electromagnet

D. Work piece fixture, work piece size & material

A. MAGNETIZATION UNIT

Basic purpose of magnetization unit is to generate the required magnetic field to

Assist the finishing process. Main parts of magnetization unit are -

 D.C. Power supply

 Electromagnet

To energize the electromagnet a constant voltage/current D.C. regulated power

supply of output voltage from 0 to 12 V and output current from 0 LO 5 A was ll
ed. By controlling the induced current from D.C.power supply the generated
magnetic field can be controlled.

B. MAGNET ROTORY MOTION UNIT

To get the finished surface, it was necessary to get relative motion between FMAB
and work piece. This unit was used to rotate the magnet and consequently LO get
the relative motion between work piece and FMAB. This facility already exists in
vertical milling machine available in our machine tool lab.
 C. ELECTROMAGNET

A round flat faced electromagnet with diame1er of 110 mm and height 55 mm was
used for machining. Electromagnet has a cen1ered N-Pole (diameter 42 mm},
surrounded with a coil (thickness = 24 mm), further surrounded by an ou1er S-Pole
(Thickness=10mm). Other dimensions of Electromagnet are given in the table-3.

D. FIXTURE AND WORKPIECE

Magnetic stainless steel was chosen as work piece ma1erial. The work piece was
made of rectangular shaped. The length of the work piece was 120 mm which is
slightly greater than the diameter of the electromagnet which was 110 mm. IL was
taken slightly more deliberately because; in this can either was no chance of
breaking of flexible brush phenomenon during finishing. During experiments 1he
work pieces were moun1cd on the table with a base plate without the fixture.
CHAPTER:-7 WORKING PROCEDURE ON MACHINE

The experiment were conducted according to following steps-

 Work pieces were initially ground by surface grinder 10 give most same
initial surface roughness value.
 After the grinding process, the work pieces were manually cleaned by 10
remove the foreign particles.
 To conduct the surface finish experiment .the work piece was mounted on
the table of MAF machine with a base plate. The work piece was made
parallel 10 the electromagnet. The work piece was made parallel in both X
and Y direction. The position of work piece in XY plane was kept in such a
way that the center of the electromagnet coincide with the center of the work
piece.
 Working gap between electr0magne1and work pieces was maintained by a
filler gauge and this gap was filled with the MAP. The amount of MAP
depends on the working gap. Percent by weight method was used 10
calculate the amount of MAP in the working gap.
 The current 10 the electromagnet was supplied and got it energized and
abrasive powder fill between the electromagnet and work piece making
FMAB. By giving rotation 10 the magnet, this FMAB perform the actual
finishing operation.
 After completing the finishing operation, work piece was again cleaned
manually using and final surface roughness value was measured.
CHAPTER:- 8 ADVANTAGES
a. A very high volume of deburring is possible.
b. Deburrs precision gears.
c. Polishes external fea1ures of various component.
d. It removes recast layer from components.
e. Effective on all metallic materials.
f. Controllability, repeatability and cost cffec1iveness.
g. Less time Consumption.

CHAPTER:- 9 APPLICATION
 Automotive -the demand for this process is increasing among car two
wheeler manufac1urers as ii is capable 10 make the surface smoother for
improved air flow and better performance of high speed engine. . This
process is capable Lo finish au1omotive and medical part .and turbine
engine component.
 Dies and Moulds - abrading medium conforms to the passage geometry,
complex shapes can be finished with case.

CHAPTER:- 10 FUTURE SCOPE

Initial cost of the machine is high; one can modify the machine by applying new
techniques.
 REFERENCES
[1]. Jain V.K,"Advance Machining Processes"Allied Publishers Pvt. Ltd. 2002

[2]. Jeong-Du Kim , Min-Seog Choi, Simulation for the prediction of surface-
accuracy in magnetic abrasive machining ,Journal of Materials Processing
Technology 53 (1995) pp 630- 642

[3]. H itomi Yamaguchi*,Takeo Shinmura, Study of an internal magnetic abrasive

finishing using a pole rotation system Discussion of the characteristic abrasive
behavior,Journal of the International Societies for Precision Engineering and
Nanotechnology 24 (2000) 237-244

[4]. Jain V.K, Kumar P., Behera P.K.,Jayswal S.C., "Effect of working gap and
circumferential speed on the performance of magnetic abrasive finishing
process",Wear, Vol 250 (2001), pp.384-390.

[5]. Yuri M.Baron ,Sung Lim Ko,Elena Repnikova,Experimental Verification of

Deburring by Magnetic Abrasive Finishing Method,(2001)

[6].Geeng-Wei Chang, Biing-Hwa Yan ,Tzong Hsu ,Study on cylindrical magnetic

abrasive finishing using unbonded magnetic abrasives, International Journal of
Machine Tools and Manufacture
Volume 42,Issue 5 ,April 2002,Pages 575-583
[7]. Singh Dhirendra K.,Jain V. K. and Raghuram V.,Parametric study of magnetic
abrasive finishing proces s, Journal of Materials Processing Technology Vol ume
149, Issues 1-3, 10June 2004,Pages 22-29

[8]. Shaohui Yin,Takeo Shinmura, Venical vibration-assisted magnetic abrasive

finishing and deburring for magnesium alloy, International Journal of Machine
Tools & Manufacture 44 (2004) 1297-1303
[9]. Singh Dhirendra K.,Jain V. K. and Raghuram V, It Komanduri, Analysis of
surface texture generated by a flexible magnetic abrasive brush, C> 2005
Published by Elsevier

[10].Y.M.Baron,S. -L. Ko and J. I. Park,Characterization of the Magnetic Abrasive

Finishing Method and Its Application to Deburring, Key Engineering Materials
Vols. 291-292 (2005) pp.291-296

[11]. S.L. Ko,Yu M. Baron and J.I. Park ,Micro deburring for precision parts using
MAF, Journal of Materials Processing Technology ,Volumes 187-188, 12June
2007, Pages 19-25

Name of Text Book

 A Text Book Of Elements of Electrical Engineering By B.T. Deshmukh

 A course in Workshop Technology Vol. 11 (Machine Tools) By B.S.
Raghuwanshi
 A Textbook of Engineering Physics By Dr. M.N. Avadhanul u and Dr. P.G.
 Kshirsagar