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Design of Experiments Technique for Evaluation of Material Removal and Surface Quality of Ductile Material

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Recent Developments in Mechanics and Design

Part of the book series: Lecture Notes in Mechanical Engineering ((LNME))

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Abstract

Magnetic field assisted abrasive flow machining (MFA-AFM) is a realistic precision finishing process used for part finishing. The process has applicability in a wide scope of industries such as aerospace, automobile, prosthetic, and tool and die manufacturing. This article primarily emphasizes on the machining mechanism of MFA-AFM intending to understand the relationships among the machining parameters, the material removal rate (MRR), and the surface quality of soft, ductile aluminum tubes. Hydraulic pressure, magnetic flux, abrasive mesh size, no. of cycles, and media are the major machining parameters that influence the machining characteristics. The experiments have been organized and conducted by employing the design of the experiment technique. The analysis of variance (ANOVA) was presented to find the contribution of all model terms influencing the MRR, and percentage change in the surface roughness (%ΔRa). The experimental results disclose that the key contributor parameters to enhance MRR and %ΔRa are hydraulic pressure and magnetic flux followed by the no. of cycles. Higher-order response models for the prediction of MRR and %ΔRa have also been presented. The optimum machining conditions have been found from numerical optimization. Surface analysis was employed to characterize the surface integrity.

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Acknowledgements

The authors wish to thank the mechanical engineering department of Baba Banda Singh Bahadur Engineering College, Fatehgarh Sahib, India, for providing the necessary facilities for experimentation on the MFA-AFM setup.

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Authors and Affiliations

  1. Mechanical Engineering Department, Baba Banda Singh Bahadur Engineering College, Fatehgarh Sahib, India

    Palwinder Singh & Lakhvir Singh

  2. Mechanical Engineering Department, Guru Nanak Dev Engineering College, Ludhiana, India

    Sehijpal Singh

Authors
  1. Palwinder Singh
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  2. Lakhvir Singh
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  3. Sehijpal Singh
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Correspondence to Palwinder Singh .

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Editors and Affiliations

  1. Department of Applied Mechanics, Indian Institute of Technology Delhi, New Delhi, Delhi, India

    Shriram Hegde

  2. Department of Mechanical Engineering, National Institute of Technology Delhi, New Delhi, Delhi, India

    Abhishek Mishra

  3. Department of Mechanical Engineering, Netaji Subhas University of Technology, New Delhi, Delhi, India

    D. K. Singh

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Singh, P., Singh, L., Singh, S. (2023). Design of Experiments Technique for Evaluation of Material Removal and Surface Quality of Ductile Material. In: Hegde, S., Mishra, A., Singh, D.K. (eds) Recent Developments in Mechanics and Design. Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-19-4140-5_2

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  • DOI: https://doi.org/10.1007/978-981-19-4140-5_2

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  • Publisher Name: Springer, Singapore

  • Print ISBN: 978-981-19-4139-9

  • Online ISBN: 978-981-19-4140-5

  • eBook Packages: EngineeringEngineering (R0)

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