Abstract
Quality and performance of the products requiring higher precision and involving moving-parts mainly depends on the surface finish and dimensional accuracy. Generally, finishing operations use fine abrasive particles in different forms along with some carrier or binding medium. Finishing operations are crucial, expensive, uncontrollable, and a labor-intensive phase in the overall production, and contribute significantly to the total production time and cost. As surface finish requirement increases, the cost of finishing operations increases exponentially. Though progress has been made in automating the finishing operations to reduce the production time to some extent, it increases the initial investment and operating costs significantly. Quality, cost, time, and efficiency of finishing operations can be improved significantly by choosing the optimum values of the process parameters. This paper presents the details of process parameters optimization of two advanced fine-finishing processes namely abrasive flow machining (AFM) and magnetic abrasive finishing (MAF), which are capable of giving nano-level surface finish, using real-coded genetic algorithms (GA). It also describes the development of a surface roughness model that was developed to form the objective function for the optimization of AFM process.
Similar content being viewed by others
References
Jain RK, Jain VK (1999) Abrasive fine-finishing processes-a review. Int J Manuf Sci Prod 2(1):55–68
Rhoades LJ (1987) Abrasive flow machining with not-so-silly putty. Met Finish 27–29, July
Rhoades LJ (1988) Abrasive flow machining. Manuf Eng 75–78
Rhoades LJ (1991) Abrasive flow machining: a case study. J Mater Process Technol 28:107–116
Pryzlenk K (1986) AFM- A process for surface finishing and deburring of the workpiece with a complicated shape by means of an abrasive laden medium, vol 22. ASME, PED, New York, pp 101–110
Perry WB (1989) Abrasive flow machining-principles and practices. In: Non-traditional Conference Proceedings, pp 121–127
Williams RE, Rajurkar KP (1989) Metal removal and surface finish characteristics in abrasive flow machining. Mechanics of deburring and surface finishing process, vol 38. ASME, PED, New York, pp 93–106
Williams RE, Rajurkar KP (1992) Stochastic modeling and analysis of abrasive flow machining. Trans ASME J Eng Ind 114(1):74–81
Benedict GF (1987) Nontraditional manufacturing processes. Marcel Dekker, Inc., New York
Williams RE (1998) Acoustic emission characteristics of abrasive flow machining. Trans ASME J Manuf Sci Eng 120:264–271
Singh S, Shan HS (2002) Development of magneto abrasive flow machining process. Int J Mach Tools Manuf 42:953–959
Gorana VK, Jain VK, Lal GK (2006) Forces prediction during material deformation in abrasive flow machining. Wear 260:128–139
Kumar TR (1998) Theoretical and experimental investigations into abrasive flow machining process. Mach Tech Thesis, I. I. T. Kanpur, July
Jain RK, Jain VK, Dixit PM (1999) Modeling of material removal and surface roughness in abrasive flow machining process. Int J Mach Tools Manuf 39:1903–1923
Jain RK, Jain VK, Kalra PK (1999) Modeling of abrasive flow machining process: a neural network approach. Wear 231:242–248
Jain RK, Jain VK (2000) Optimum selection of machining conditions in abrasive flow machining using neural network. J Mater Proc Technol 108(1):62–67
Machinability Data Center (1980) Machining data handbook, vol 2, 3rd edn. Metcut Research Associates Inc., Cincinnati, Ohio
Shinmura T, Takazawa K, Hatano E, Aizawa T (1985) Study on magnetic abrasive process: process principle and finishing possibility. Bull Jpn Soc Precis Eng 19(1):54–55
Shinmura T, Takazawa K, Hatano E, Aizawa T (1984) Study on magnetic abrasive process: finishing characteristics. Bull Jpn Soc Precis Eng 18(4):347–348
Shinmura T, Takazawa K, Hatano E (1986) Study on magnetic abrasive process: effects of machining fluid on finishing characteristics. Bull Jpn Soc Prec Eng 20(1):52–54
Shinmura T, Takazawa K, Hatano E (1987) Study on magnetic abrasive finishing: effects of various types magnetic abrasives on finishing characteristics. Bull Jpn Soc Precis Eng 21(2):139–141
Shinmura T, Takazawa K, Hatano E (1985) Study on magnetic abrasive process: application to edge finishing. Bull Jpn Soc Precis Eng 19(3):218–220
Fox M, Agrawal K, Shinmura T (1994) Magnetic abrasive finishing of rollers. Ann CIRP 43(1):181–184
Shinmura T, Takazawa K, Hatano E (1985) Study on magnetic abrasive process: application to plane finishing. Bull Jpn Soc Precis Eng 19(4):289–291
Shinmura T, Aizawa T (1989) Study on magnetic abrasive finishing process: development of plane finishing apparatus using a stationary type electromagnet. Bull Jpn Soc Precis Eng 23(3):236–239
Shinmura T, Aizawa T (1989) Study on internal finishing of non-ferromagnetic tubing by magnetic abrasive machining process. Bull Jpn Soc Precis Eng 23(1):37–41
Singh DK, Jain VK, Raghuram V (2004) Parametric study of magnetic abrasive finishing process. J Mater Process Technol 149:22–29
Singh DK, Jain VK, Raghuram V, Koanduri R (2005) Analysis of surface texture generated by a flexible magnetic abrasive brush. Wear 259:1254–1261
Singh DK, Jain VK, Raghuram V (2005) Experimental investigations into forces acting during a magnetic abrasive finishing process. Int J Adv Manuf Technol
Singh DK, Jain VK, Raghuram V (2005) On the performance analysis of flexible magnetic abrasive brush. Mach Sci Tech 9:601–619
Kremen GZ, Elsayed EA, Ribeiro JL (1994) Machining time estimation for magnetic abrasive processes. Int J Prod Res 32:2817–2825
Kim JD, Choi MS (1995) Simulation for the prediction of surface-accuracy in magnetic abrasive machining. J Mater Process Technol 53:630–642
Kremen GZ, Elsayed EA, Rafalovich VI (1996) Mechanism of material removal in the magnetic abrasive process and the accuracy of machining. Int J Prod Res 34:2629–2638
Jayaswal SC, Jain VK, Dixit PM (2005) Modeling and simulation of magnetic abrasive finishing process. Int J Adv Manuf Technol
Wang YL, Wang ZS (1988) An analysis of the influence of plastic indentation on three-body abrasive wear of metals. Wear 122:123–133
Deb K (1995) Optimization for engineering design: algorithms and examples. Prentice-Hall of India Pvt. Ltd., New Delhi
Goldberg, DE (2000) Genetic algorithms: in search optimization and learning. Pearson Education Asia Pvt. Ltd., (second Indian reprint)
Bagchi TP (1999) Multiobjective scheduling by genetic algorithms. Kluwer Academic Publishers, London
Jain VK, Adsul SG (2000) Experimental investigation into abrasive flow machining. Int J Mach Tools Manuf 40:1003–1021
Gorana VK, Jain VK, Lal GK (2004) Experimental investigations into cutting forces and active grain density during abrasive flow machining. Int J Mach Tools Manuf 44:201–211
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Jain, N.K., Jain, V.K. & Jha, S. Parametric optimization of advanced fine-finishing processes. Int J Adv Manuf Technol 34, 1191–1213 (2007). https://doi.org/10.1007/s00170-006-0682-4
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-006-0682-4