Experimental Investigation of Process Parameters of Al-SiC-B4C MMCs Finished by a Novel Magnetic Abrasive Flow Machining Setup

Abrasive flow machining (AFM) is one of the non-conventional finishing processes used to attain good surface quality and high material removal. However, limited attempts have been made improve performance these processes. This paper presents a novel magnetic abrasive (MAFM) setup fabricated by adding magnetization effect in which nylon fixture permanent magnets are replaced newly aluminium coil-type magnets, respectively. Inner cylindrical surfaces hybrid Al/SiC/B4C metal matrix composites (MMCs) finished MAFM process. One variable at time (OVAT) approach for studying 6 input parameters, extrusion pressure (Ep), number cycles (N), abrasives concentration (C), workpiece (Wp), mesh size (M), flux density (Mf) upon response removal rate (MRR) change roughness (?Ra). The experimental results obtained MRR ?Ra show significant improvement from 3.92 7.68 ?g/s 0.49 0.74 ?m, respectively due increase 1 9 Mpa. was reduced 6.89 6.78 0.46 0.22 with an 80 400. variation 40 60 % shows 4.51 6.42 ?g/s; whereas, there negligible on comes out 3.82 3.86 ?m. MMCs, experimentation decline 5.12 3.85 0.77 0.42 happened because percentage reinforcement SiC 7 B4C 3 Al-6063. An 50 250 both 1.79 3.75 0.97 1.86 Variation also significantly improves 1.35 3.17 0.38 1.06 respectively, when it varied 0.15 - 0.45 Tesla. work carried overall using process finds wide range applications like surgical instruments, mechanical components, aerospace industry, electronics etc. HIGHLIGHTS MMCs (Al/SiC/B4C) play role laden media acts as cutting tool OVAT investigating parametric pressure, parameters affecting GRAPHICAL ABSTRACT