An integrated application of chemo-ultrasonic approach for improving surface finish of Si (100) using double disk magnetic abrasive finishing

A very precise surface finish is desirable in manufacturing semiconductors, medical equipment, and aerospace parts. The examinations on magnetic abrasive finishing (MAF) processes are being done for the modern industry. This newly developed process is serving the industry to achieve the desired level of precision and surface finish. This research represents the MAF of aluminum pipes using adhesive magnetic abrasive particles. The different process parameters were optimized using the Response Surface Methodology (RSM) method to gain an in-depth analysis of surface roughness in terms of roughness improvement rate (RIR), and material removal rate (MRR). The achieved maximum RIR and MRR was 81.49% and 2.74mg/min, respectively. The finished workpieces were microscopically investigated by scanning electron microscopy (SEM) to further study the mechanism of MAF process.

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Surface texture improvement of magnetic and non magnetic materials using magnetic abrasive finishing process

Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science ◽

10.1177/0954406220970590 ◽

2020 ◽

pp. 095440622097059

Author(s):

Kamepalli Anjaneyulu ◽

Gudipadu Venkatesh

Keyword(s):

Surface Roughness ◽

Surface Finish ◽

Surface Texture ◽

Magnetic Particles ◽

Supply Voltage ◽

Initial Surface ◽

Magnetic Abrasive Finishing ◽

Abrasive Finishing ◽

Change In Mean ◽

Al 2024

The present study focused on surface texture characteristics of magnetic material, Mild steel (MS) as well as nonmagnetic material, Aluminum 2024 (Al 2024) alloy with the application of a laboratory-developed magnetic abrasive finishing (MAF) process. MAF is one of the unconventional finishing processes to attain a satisfactory finishing level up to nanoscale. In MAF, the surface finish is controlled by a flexible magnetic abrasive brush (FMAB) which has a combination of abrasives (Al2O3, SiC, etc.) and magnetic particles (iron powder). The experiments were planned using (L27) full factorial design, different levels of weight percentage of abrasives (20–30%), speed of the electromagnet (180–2100rpm), and electromagnet supply voltage (30–50 V) were varied to enhance the surface responses. The responses considered were % improvements of change in the surface finish (%ΔRa), change in average peak to valley height (%ΔRz), change in total profile height (%ΔRt), and change in mean square root surface finish (%ΔRq). Analysis of variances (ANOVA) was evaluated and discussed. It is observed that the speed of the electromagnet and voltage are the most influencing variable parameters that most impacted on the responses. Surface roughness was measured before and after the MAF processing of MS and Al 2024 using a Suftronic S-100 surface roughness tester. The obtained surface morphology was examined by Scanning Electron Microscopy (SEM). It was observed that MS has %ΔRa = 83, %ΔRz = 65, %ΔRt = 65.5 and %ΔRq = 72.6 while Al 2024 has %ΔRa = 65, %ΔRz =50, %ΔRt = 51 and %ΔRq = 55 with noticeable surface texture improvement compared to the initial surface roughness obtained using surface grinding process.

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A Comprehensive Review on Magnetic Abrasive Finishing Process

Advanced Engineering Forum ◽

10.4028/www.scientific.net/aef.18.1 ◽

2016 ◽

Vol 18 ◽

pp. 1-20 ◽

Cited By ~ 2

Author(s):

Mohannad Naeem Houshi

Keyword(s):

Surface Finish ◽

Low Cost ◽

High Surface ◽

Functional Requirements ◽

Workpiece Surface ◽

Magnetic Abrasive Finishing ◽

Finishing Process ◽

Abrasive Finishing ◽

Superior Surface ◽

Finishing Processes

In the nanotechnology era, the need for products with high quality and surfaces with free-from damage has become an urgent necessity. Many components in the precision industries such as electronics, automobile, medical, and aviation require high surface finish to meet their functional requirements, such as, reducing fluid flow resistance, friction, optical losses and increase fatigue strength. However, the scale of such surface quality cannot be achieved by traditional finishing methods. To overcome these limitations, many advanced finishing processes have been developed such as abrasive flow finishing, magnetorheological fluid finishing, magnetic float polishing, and chemical mechanical polishing and magnetic abrasive finishing. Magnetic abrasive finishing (MAF) is one of advanced finishing processes which offers superior surface finish over conventional finishing processes, because of its self-adaptability to finish of different geometric shapes, its a gentle tool which does not impact workpiece surface, its capability to polish advanced engineering materials and its low cost. This article has been focused on MAF, as well as reviewing of advanced finishing processes. The recent researches and challenges of MAF have been discussed as well.

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Use of chemical oxidizers with alumina slurry in Double Disk Magnetic Abrasive Finishing for improving surface finish of Si (100)

Journal of Manufacturing Processes ◽

10.1016/j.jmapro.2018.02.007 ◽

2018 ◽

Vol 32 ◽

pp. 138-150 ◽

Cited By ~ 7

Author(s):

Kheelraj Pandey ◽

Pulak M Pandey

Keyword(s):

Surface Finish ◽

Magnetic Abrasive Finishing ◽

Abrasive Finishing

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Analysis of Surface Finish Improvement during Ultrasonic Assisted Magnetic Abrasive Finishing on Chemically treated Tungsten Substrate

Procedia Manufacturing ◽

10.1016/j.promfg.2017.07.040 ◽

2017 ◽

Vol 10 ◽

pp. 136-146 ◽

Cited By ~ 8

Author(s):

Nitesh Sihag ◽

Prateek Kala ◽

Pulak M. Pandey

Keyword(s):

Surface Finish ◽

Magnetic Abrasive Finishing ◽

Abrasive Finishing ◽

Chemically Treated ◽

Ultrasonic Assisted ◽

Tungsten Substrate

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Experimental Investigation of the Magnetic Abrasive Finishing of SS310s

Materials Testing ◽

10.1515/mt-2021-0014 ◽

2021 ◽

Vol 63 (9) ◽

pp. 878-884

Author(s):

Kandasamy Suganeswaran ◽

Rathinasamy Parameshwaran ◽

Thangamuthu Mohanraj ◽

Balasubramaniyam Meenakshipriya ◽

Nagarajan Nithyavathy

Keyword(s):

Process Parameters ◽

Surface Finish ◽

Removal Rate ◽

Desirability Function ◽

Wear Test ◽

Magnetic Flux Density ◽

Element Analysis ◽

Magnetic Abrasive Finishing ◽

Abrasive Finishing ◽

Optical Microscopic Image

Abstract Magnetic abrasive finishing (MAF), an unconventional process, enhances the surface finish of a material. The current research focuses on its use with SS310s. The finite element analysis (FEA) result shows the effect of control parameters on the magnetic flux density. In FEA analysis, it was decided to maintain an air gap of 1.5-2 mm and a voltage of 10-20 V. A response surface methodology (RSM) desirability function is used to identify the optimal process parameters. Experiments are conducted for optimizing the process parameters like voltage, rotational speed, machining gap, mixing ratio, and mesh number to enhance the material removal rate (MRR) and surface roughness (Ra). A series of 62 experiments are conducted using optimized process parameters at different levels. Moreover, analysis of variance (ANOVA) is used to identify the percentage contribution of each process parameter in %ΔRa and MRR. From this, the mesh number of the abrasives plays an important role in the finishing process owing to the increased number of cutting edges and because of the uniform normal force (Fn) distribution. The optical microscopic image result and the wear test confirms that the surface finish of SS310s has been improved using MAF.

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Improve the Micro-hardness of Single Point Incremental Forming Product Using Magnetic Abrasive Finishing

Engineering and Technology Journal ◽

10.30684/etj.v38i8a.906 ◽

2020 ◽

Vol 38 (8A) ◽

pp. 1137-1142

Author(s):

Baqer A. Ahmed ◽

Saad K. Shather ◽

Wisam K. Hamdan

Keyword(s):

Vickers Hardness ◽

Feed Rate ◽

Incremental Forming ◽

Single Point ◽

Single Point Incremental Forming ◽

Step Size ◽

Coil Current ◽

Magnetic Abrasive Finishing ◽

Finishing Process ◽

Abrasive Finishing

In this paper the Magnetic Abrasive Finishing (MAF) was utilized after Single Point Incremental Forming (SPIF) process as a combined finishing process. Firstly, the Single Point Incremental forming was form the truncated cone made from low carbon steel (1008-AISI) based on Z-level tool path then the magnetic abrasive finishing process was applied on the surface of the formed product. Box-Behnken design of experiment in Minitab 17 software was used in this study. The influences of different parameters (feed rate, machining step size, coil current and spindle speed) on change in Micro-Vickers hardness were studied. The maximum and minimum change in Micro-Vickers hardness that achieved from all the experiments were (40.4 and 1.1) respectively. The contribution percent of (feed rate, machining step size, coil current and spindle speed) were (7.1, 18.068, 17.376 and 37.894) % respectively. After MAF process all the micro surface cracks that generated on the workpiece surface was completely removed from the surface.

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Process parameter optimization for the magnetic abrasive finishing of SS310s steel

Materials Testing ◽

10.3139/120.111467 ◽

2020 ◽

Vol 62 (2) ◽

pp. 157-164 ◽

Cited By ~ 1

Author(s):

Kandhasamy Suganeswaran ◽

Rathinasamy Parameshwaran ◽

Thangamuthu Mohanraj ◽

Balasubramaniyam Meenakshipriya

Keyword(s):

Parameter Optimization ◽

Process Parameter ◽

Process Parameter Optimization ◽

Magnetic Abrasive Finishing ◽

Abrasive Finishing

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Study the effect of concentration ratio (magnetic abrasive powder and castor oil) in magnetic abrasive finishing process

Materials Today Proceedings ◽

10.1016/j.matpr.2020.10.160 ◽

2020 ◽

Author(s):

Raman Kumar

Keyword(s):

Castor Oil ◽

Concentration Ratio ◽

Magnetic Abrasive Finishing ◽

Abrasive Powder ◽

Finishing Process ◽

Abrasive Finishing

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Development of a New Finishing Process Combining a Fixed Abrasive Polishing with Magnetic Abrasive Finishing Process

Machines ◽

10.3390/machines9040081 ◽

2021 ◽

Vol 9 (4) ◽

pp. 81

Author(s):

Yanhua Zou ◽

Ryunosuke Satou ◽

Ozora Yamazaki ◽

Huijun Xie

Keyword(s):

Alumina Ceramic ◽

Ceramic Plate ◽

Polishing Process ◽

High Quality ◽

Influence Of Process Parameters ◽

Magnetic Abrasive Finishing ◽

Nano Scale ◽

Finishing Process ◽

Abrasive Finishing ◽

Fixed Abrasive

High quality, highly efficient finishing processes are required for finishing difficult-to-machine materials. Magnetic abrasive finishing (MAF) process is a finishing method that can obtain a high accuracy surface using fine magnetic particles and abrasive particles, but has poor finishing efficiency. On the contrary, fixed abrasive polishing (FAP) is a polishing process can obtain high material removal efficiency but often cannot provide a high-quality surface at the nano-scale. Therefore, this work proposes a new finishing process, which combines the magnetic abrasive finishing process and the fixed abrasive polishing process (MAF-FAP). To verify the proposed methodology, a finishing device was developed and finishing experiments on alumina ceramic plates were performed. Furthermore, the mechanism of the MAF-FAP process was investigated. In addition, the influence of process parameters on finishing characteristics is discussed. According to the experimental results, this process can achieve high-efficiency finishing of brittle hard materials (alumina ceramics) and can obtain nano-scale surfaces. The surface roughness of the alumina ceramic plate is improved from 202.11 nm Ra to 3.67 nm Ra within 30 min.

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