OPTIMIZATION OF PROCESS PARAMETERS USING CNT PARTICLE BASED ABRASIVE MEDIA USED FOR FINISHING OF BRASS WORKPIECE BY ABRASIVE FLOW MACHINING

Abstract

Abrasive flow machining is a nontraditional finishing process and is used to polish metallic components, internal inaccessible cavities or recesses using a semi liquid paste. It was developed to deburr, polish, and radius surfaces having complex geometries and edges by flowing abrasives with a viscoelastic polymer (called as media) over them. Abrasion occurs wherever the medium passes through the highly restrictive passage. In this work, two way abrasive flow machining is used to optimize the material removal and % improvement in surface roughness on brass material. In this study three parameter are used level of carbon nano tube, level of pressure, number of cycle. The abrasive media is formed with the combination of polymer and gel, abrasive particle and carbon nano tube (CNT). Polymer is made with the help of some chemical like as silicon oil , boric acid and ferric chloride (FeCl3.6H2o) and ammonia carbonates (NH4CO3). This media is mixed with the level of CNT and experiment is conducted on brass work-piece. Three process parameter level of CNT, Extrusion pressure and Number of cycle have been used for experiment to study the effect of these process parameter on % improvement in surface roughness and material removal of brass work-piece. L9 orthogonal array based on Taguchi method has been used to study the effect of various process parameter on selected on response parameter. All three parameter affects the material removal and surface finish, by using level of CNT material removal continuosly increased among other parameter while surface roughness is improved up to second level after decreases. In case of No of cycle from first level to second level material is decreased after that increased but for surface roughness improvement is little bit significant. Third parameter extrusion pressure have little bit significant on MR but highly significant for surface roughness improvement. Effect of CNT on material removal is continuosly increases. The percentage contribution of CNT is 14.98%.and the effect of other parameter on MR are percentage contribution of Extrusion pressure is 15.56% and the percentage contribution of Number of cycle is 21.22%. Optimum level is selected for material removal is C3 P1 N3. Effect of CNT on improvement on surface finish the percentage contribution of CNT is maximum is 23.84%.The percentage contribution of number of cycle is 23.14% and extrusion pressure which contribute 15.90%.