Design & Development of Automated Five Axis CNC Ball End Magnetorheological Finishing Machine

Dilshad Ahmad Khan and his team member Faiz Iqbal, Zafar Alam won the Appreciation award for the project Design & Development of Automated Five Axis CNC Ball End Magnetorheological Finishing Machine. He carried his project work under the guidance of Dr. Sunil Jha, Indian Institute of Technology, Delhi.

The project is an innovation and technology based work aimed at providing nano level finish on various materials of complex shapes and size. This project is related to the design and development of a fully automated five axis CNC ball end magnetorheological finishing (BEMRF) setup from the conceptual idea to an industry standard machine. The developed machine caters to the demand of today's advanced industries which deals in finishing of 3-D dies, high precision lenses, orthopaedic implants, jewelleries and gems etc. In the first phase of the project an idea is conceptualized to finish 3-D complex surfaces using magnetorheological polishing (MRP) fluid. After checking the feasibility of the concept, a BEMRF tool is developed which is later mounted on a CNC machine setup. The newly developed finishing process is used to finish ferromagnetic as well as nonmagnetic materials of complex shapes and sizes using specially prepared magnetorheological polishing fluid. Apart from nano finishing on the surfaces, the measurement of surface roughness of the workpiece is also needed to be wear free which is not the case in stylus based measurement systems. Therefore, a non-contact roughness measurement instrument (confocal sensor) is incorporated in BEMRF machine. The confocal sensor is light, compact and easily mounted on the BEMRF tool for quick and error free measurement of surface roughness after the BEMRF process. In BEMRF machine the forces can be controlled automatically thereby enabling the user to select suitable force according to the material to be finished.

Anil Sahasrabudhe, Chairman of the All India Council for Technical Education, honored Dilshad Ahmad Khan, research scholar, Indian Institute of Technology, Delhi, with the prestigious Gandhian Young Technological Innovation (GYTI) Appreciation award 2017  at Rashtrapati Bhavan.


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