CFD Modeling and Optimization of Magneto-rheological Abrasive Flow Finishing (MRAFF) Process

Abstract

A modern nano finishing technique called magnetorheological abrasive flow finishing (MRAFF), which is simply a combined hybrid form of abrasive flow machining (AFM) process and magnetorheological finishing (MRF) process, has been designed for micro finishing of parts even with difficult geometry for a broad range of industrial purposes. In the present work, a model for the prediction of removal of material and surface roughness has been estimated. An effort has been made to study the flow passing through the stainless steel workpiece by CFD modeling in ANSYS 15.0 FLUENT. By assuming the medium as Bingham plastic various parameters affecting the surface roughness has been calculated. Also a theoretical calculation is made for the model if no magnetic field is applied and then comparative study of the two models is proposed. An optimization of the process has also been carried out. With the help of SN Ratio plot and Means plot optimized value of input parameters has been found out to achieve better surface finish.