PARAMETRIC OPTIMIZATION OF CNTs PARTICLE BASED ABRASIVE MEDIA USED IN ABRASIVE FLOW MACHINING PROCESS FOR FINISHING OF CAST IRON WORKPIECE

Abstract

Over recent years a significant amount of research has been undertaken to develop a process which can machine the component with higher MR and surface finish (Ra value). AFM is a relatively new process in the field of modern machining/finishing. It offers brilliant surface finish, economy and dimensional accuracy of the machined parts. Its applications have rapidly diversified into the automobile, pharmaceutical, chemical, production, defence, space and aeronautics industry. In this report, a thorough study of present developments in the field of AFM was carried out. The indigenous new vertical double acting AFM setup is designed and developed with varying ranges of process parameters. Nano particles have extraordinary properties over available abrasives, so to enhance MR and surface finish nano particles can be used. Nanotubes find applications as additives to various structural materials so an attempt is made to CNTs as abrasive with the carrier and Al2O3 to machine the cast iron workpiece. Study and synthesis of iron filled CNTs is discussed and it is characterized through Transmission Electron Microscope (TEM) images. In this study an endeavour was carried out to develop media (carrier+Al2O3+CNTs) as an alternative to the exiting available media. Experiments have been conducted using the Taguchi L9 OA method and the relevant dependencies have been found out by carrying out ANOVA analysis It is found that the developed media is flexible to be used in AFM process and performance study reveals that the developed media yields a good surface finish and material removal (MR).