Vol.:(0123456789) 1 3 Journal of the Brazilian Society of Mechanical Sciences and Engineering (2020) 42:302 https://doi.org/10.1007/s40430-020-02375-6 TECHNICAL PAPER Material removal analysis of hybrid EDM‑assisted centrifugal abrasive fow machining process for performance enhancement Parvesh Ali 1  · R. S. Walia 2  · Qasim Murtaza 1  · Ranganath Muttanna Singari 1 Received: 4 December 2018 / Accepted: 21 April 2020 © The Brazilian Society of Mechanical Sciences and Engineering 2020 Abstract Finishing of metallic machine components is a prime requirement for the better performance and longer product life cycle. To get highly fnished machine components, a number of conventional and non-conventional fnishing processes have evolved in recent times to overcome constraints due to shape and properties of materials. This paper discusses a new hybrid technique, Thermal additive centrifugal abrasive fow machining (TACAFM) which is a combination of centrifugal force- assisted abrasive fow machining and electrical discharge machining (EDM) process. In this process abrasive particles move coaxially with workpiece and also rotate inside the hollow workpiece with the help of a rotating system and also generated thermal efect as in EDM process. Due to the movement of abrasive particles along with rotation, Coriolis efect plays a major role in determining the position of abrasives at any time. Therefore, in the present study, Coriolis component efect is incorporated in the mathematical model to predict the material removal in TACAFM. Also, its parameters, viz current, abrasive concentration, pressure, duty cycle, and rotation of electrode, were optimized using response surface methodology. A simulation model is also presented using Ansys ® 15 software to analyze the efect of temperature around the work surface when varying gap between the electrode and work surface along with rotational speed of electrode. Experimental results show a good agreement with the mathematical model. The experiments conducted on the developed process show average 44.34% improvement in material removal and average 39.74% improvement in surface fnish, respectively. Keywords Current · Finishing · Rotation · Thermal spark mechanism · Hybrid machining 1 Introduction Due to the rapid development in fnishing technology, there is a high demand of accurate and precise dimension compo- nents in the industry. Even a small scratch can be responsible for failure of a component in dynamic loading as the scratch becomes stress raiser. Recently, fnishing industry has been using conventional fnishing processes such as honing and lapping, which restricts the workpiece to a particular shape. To overcome the shape factor, there is a need to develop non- conventional fnishing processes such as abrasive fow machin- ing (AFM). AFM process has an edge over the conventional processes because it uses a semisolid media such as combina- tion of polymer, gel and abrasives which fow at high pressure through the restrictive path and provide surface fnishing by removing the material in the form of micro/nano chips. The non-conventional fnishing process is being used for nano fn- ishing of the complex machined geometry of workpiece sur- faces that cannot be obtained through conventional fnishing technique. Jain et al. [1] reported that the abrasive laden media used for fnishing was viscous enough to hold the abrasive particles together for abrasion mechanism in AFM process. Sankar et al. [2] stated that AFM process removes the material in the range of 1–10 µm. However, large imper- fections in the material cannot be corrected by this pro- cess because it removes low amount of material uniformly from the workpiece surface. Therefore, AFM process has a limitation of low material removal that leads to the devel- opment of new hybrid techniques such as clubbing AFM Technical Editor: Lincoln Cardoso Brandao. * R. S. Walia waliaravinder@yahoo.com * Qasim Murtaza qasimmurtaza@gmail.com 1 Department of Mechanical Engineering, Delhi Technological University, Delhi, India 2 Department of Production and Industrial Engineering, Punjab Engineering College, Chandigarh, India