This happened because there was a percentage change of reinforcement of SiC from 9 to 7 % and B4C from 1 to 3 % in Al-6063. The MMCs, which are used for the experimentation shows a decline in MRR and ΔRa from 5.12 to 3.85 μg/s and 0.77 to 0.42 μm, respectively. The variation in concentration of abrasives from 40 to 60 % shows an improvement in MRR from 4.51 to 6.42 μg/s whereas, there is a negligible effect on ΔRa which comes out from 3.82 to 3.86 μm. The MRR and ΔRa was reduced from 6.89 to 6.78 μg/s and 0.46 to 0.22 μm, respectively with an increase in mesh number of abrasives from 80 to 400. The experimental results obtained for MRR and ΔRa show a significant improvement from 3.92 to 7.68 μg/s and 0.49 to 0.74 μm, respectively due to the increase of the extrusion pressure from 1 to 9 Mpa. One variable at a time (OVAT) approach is used for studying the effect of 6 input parameters, extrusion pressure (Ep), the number of cycles (N), abrasives concentration (C), workpiece material (Wp), abrasive mesh size (M), and magnetic flux density (Mf) upon response parameters, material removal rate (MRR) and change in surface roughness (ΔRa). Inner cylindrical surfaces of hybrid Al/SiC/B4C metal matrix composites (MMCs) are finished by the MAFM process. This paper presents a novel magnetic abrasive flow machining (MAFM) setup fabricated by adding a magnetization effect in which a nylon fixture and permanent magnets are replaced by a newly fabricated aluminium fixture and coil-type magnets, respectively. However, limited attempts have been made to improve the performance of these processes. Abrasive flow machining (AFM) is one of the non-conventional finishing processes used to attain good surface quality and high material removal.
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