Theoretical and Experimental Investigation on Surface Roughness of Straight Bevel Gears Using a Novel Magnetorheological Finishing Process

Wear ◽  
2021 ◽  
pp. 203693
Author(s):  
Kunal Arora ◽  
Anant Kumar Singh
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Magnetorheological Finishing ◽  
Bevel Gears ◽  
Finishing Process

Experimental investigation into polishing of monocrystalline silicon wafer using double-disc chemical assisted magnetorheological finishing process

2021 ◽  
pp. 095440622098384
Author(s):  
Mayank Srivastava ◽  
Pulak M Pandey
Keyword(s):  
Surface Roughness ◽  
Silicon Wafer ◽  
Flow Rate ◽  
Silicon Wafers ◽  
Monocrystalline Silicon ◽  
Slurry Flow ◽  
Magnetorheological Finishing ◽  
Finishing Process ◽  
Process Factors ◽  
Slurry Flow Rate

In the present work, a novel hybrid finishing process that combines the two preferred methods in industries, namely, chemical-mechanical polishing (CMP) and magneto-rheological finishing (MRF), has been used to polish monocrystalline silicon wafers. The experiments were carried out on an indigenously developed double-disc chemical assisted magnetorheological finishing (DDCAMRF) experimental setup. The central composite design (CCD) was used to plan the experiments in order to estimate the effect of various process factors, namely polishing speed, slurry flow rate, percentage CIP concentration, and working gap on the surface roughness ([Formula: see text]) by DDCAMRF process. The analysis of variance was carried out to determine and analyze the contribution of significant factors affecting the surface roughness of polished silicon wafer. The statistical investigation revealed that percentage CIP concentration with a contribution of 30.6% has the maximum influence on the process performance followed by working gap (21.4%), slurry flow rate (14.4%), and polishing speed (1.65%). The surface roughness of polished silicon wafers was measured by the 3 D optical profilometer. Scanning electron microscopy (SEM) and atomic force microscopy (AFM) were carried out to understand the surface morphology of polished silicon wafer. It was found that the surface roughness of silicon wafer improved with the increase in polishing speed and slurry flow rate, whereas it was deteriorated with the increase in percentage CIP concentration and working gap.

Experimental Investigation of Vibratory Finishing Process

2014 ◽  
Author(s):  
Xiaozhong Song ◽  
Rahul Chaudhari ◽  
Fukuo Hashimoto
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Metal Removal ◽  
Contact Forces ◽  
Chemical Solution ◽  
Impact Frequency ◽  
Vibratory Finishing ◽  
Factors Affecting ◽  
Finishing Process ◽  
Chemical Solutions

The vibratory finishing process is widely used for finishing metal components. An experimental investigation is reported on the factors affecting the metal removal and resultant surface roughness during vibratory finishing including the influence of chemical solutions. The effect of process parameters such as media size and impact frequency is studied by measuring the contact forces. A method to investigate the effect of chemical solution and to optimize the processing time to achieve desired resultant surface roughness is presented.

Magnetorheological finishing of silicon for nanometric surface generation: An experimental and simulation study

2018 ◽  
Vol 29 (11) ◽  
pp. 2456-2464 ◽  
Author(s):  
Neha Khatri ◽  
Suman Tewary ◽  
Xavier J Manoj ◽  
Harry Garg ◽  
Vinod Karar
Keyword(s):  
Molecular Dynamics ◽  
Surface Roughness ◽  
Surface Quality ◽  
Surface Finish ◽  
Atomic Scale ◽  
Dynamics Simulation ◽  
Surface Generation ◽  
Magnetorheological Finishing ◽  
X Ray ◽  
Finishing Process

Silicon mirrors are essential for guiding the X-ray beam and focusing it to a specific location. These mirrors using total internal reflection require super smooth surface finish due to small wavelength of X-ray. Magnetorheological finishing is a computer-controlled technique used in the production of high-quality optical lenses. This process utilizes polishing slurries based on magnetorheological fluids, whose viscosity changes with the change in magnetic field. In this work, polishing potential of silicon mirrors by magnetorheological finishing process is examined to achieve nanometric surface finish for X-ray applications. The individual effect of parameters such as magnetizing current, working gap, rotational speed on surface roughness is investigated, and optimized parameters are identified. To investigate the physical essence underlying magnetorheological finishing process, the molecular dynamics simulations are used. Molecular dynamics simulation is used to study the atomic-scale removal mechanism of single-crystalline silicon in magnetorheological finishing process and attention is paid to study the effect of gap between the tool and the workpiece on surface quality. The outcome is promising and the final surface roughness achieved is as low as 6.4 nm. The surface quality is analyzed in terms of arithmetic roughness, power spectral density, and image analysis of scanning electron microscopy for uniform evaluation.

Experimental investigation and machine parameter optimization for nano finishing of fused silica using magnetorheological finishing process

Optik ◽  
2021 ◽  
Vol 226 ◽  
pp. 165908
Author(s):  
Mahender Kumar Gupta ◽  
D Dinakar ◽  
Inder Mohan Chhabra ◽  
Sunil Jha ◽  
Buchi Suresh Madireddy
Keyword(s):  
Experimental Investigation ◽  
Parameter Optimization ◽  
Fused Silica ◽  
Machine Parameter ◽  
Magnetorheological Finishing ◽  
Finishing Process

New Viscoelastic Magnetic Abrasive and its Surface Finishing Process

2011 ◽  
Vol 314-316 ◽  
pp. 300-303 ◽  
Author(s):  
Wen Hui Li ◽  
Xiu Hong Li
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Practical Problem ◽  
Positive Impact ◽  
Complex Surface ◽  
Surface Finishing ◽  
Simple Test ◽  
Test Device ◽  
Finishing Process ◽  
Magnetic Abrasives

In order to solve the practical problem of deburring and surface finishing of internal hole surface, mold cavity, complex surface, etc., a new viscoelastic magnetic abrasives is proposed based on analysis of field characteristic and existing finishing process. Viscoelastic magnetic abrasives are prepared, and motion locus of abrasives are discussed. An experimental investigation is engaged on direct hole, keyway surface through a simple test device designed by ourselves. Theoretical analysis and experiments show that all burrs is removed, the edges are rounded off and the surface is smooth, the value of surface roughness Ra drops from 0.53μm to 0.05μm. It’s successful application will effectively solve the practical difficulty of deburring and surface finishing for special shapes such as groove, keyway, etc. and fulfil the quantitative finishing of complex surfaces. It will produce a positive impact on precision surface finishing technology.

A Novel Ball End Magnetorheological Finishing Process

2014 ◽  
Author(s):  
Anant Kumar Singh ◽  
Sunil Jha ◽  
Pulak M. Pandey
Keyword(s):  
Surface Roughness ◽  
Outer Core ◽  
Free Form ◽  
Continuous Heating ◽  
Magnetorheological Finishing ◽  
Noise And Vibration ◽  
Magnetic Coil ◽  
Finishing Process ◽  
Finishing Tool ◽  
Polishing Fluid

A novel ball end magnetorheological finishing process was developed for performing stable and controllable finishing operation on flat as well as 3D free form features of magnetic or non-magnetic materials. The main innovation in this process was generating a magnetic flux density at the end of a cylindrical tool that facilitates the shaping of the magnetorheological polishing fluid in a fashion to resemble like a ball nose cutter. A 4-axis motion controller program directs the resembled polishing fluid to follow the surface to be finished. This paper focuses on the various stages of the development of a novel finishing process. This leads to significant improvement in process performance in terms of smooth controllable functionality, percentage reduction in surface roughness, surface textures at microscopic level of the workpiece surfaces. In the initial stage of development, the magnetorheological cylindrical finishing tool was made to rotate as a whole during the finishing operation with all its constituent components like inner core, magnetic coil and outer core. In this stage, there was no provision of cooling magnetic coil because magnetic coil was rotated with the rotation of the finishing tool during finishing operation. Therefore, it was difficult to incorporate any cooling arrangement over the outer surface of magnetic coil to cool it continuously. Hence, the tool was limited to shorter time of finishing operation due to continuous heating of magnetic coil. Also, some other additional limitations were noticed such as constraint on magnetic coil to produce higher magnetic field, noise and vibration during the finishing operation. These limitations resulted in low effectiveness of finishing operation. To overcome these specific limitations which were observed after initial development of finishing setup, the limitations were overcome by redesigning of cylindrical finishing tool with stationary magnetic coil (integrated with cooling coils) and only central core was allowed to rotate during operation without the outer core. This resulted in smooth rotational motion of the tool without much noise and vibration during finishing operation. The experiments were performed on flat magnetic material workpiece using the modified magnetorheological cylindrical finishing tool. The surface finish obtained was 23.7 nm from the initial surface roughness of 126.1 nm in 30 min with continuous cooling of magnetic coil.

Experimental investigation on magnetorheological finishing process parameters

2021 ◽  
Author(s):  
Abdul Wahab Hashmi ◽  
Harlal Singh Mali ◽  
Anoj Meena ◽  
Irshad Ahamad Khilji ◽  
Chaitanya Reddy Chilakamarry ◽  
...  
Keyword(s):  
Experimental Investigation ◽  
Process Parameters ◽  
Magnetorheological Finishing ◽  
Finishing Process

Toward Magnetorheological Finishing of Magnetic Materials

2007 ◽  
Vol 129 (5) ◽  
pp. 961-964 ◽  
Author(s):  
Shai N. Shafrir ◽  
John C. Lambropoulos ◽  
Stephen D. Jacobs
Keyword(s):  
Magnetic Material ◽  
Surface Roughness ◽  
Magnetic Materials ◽  
Material Removal ◽  
Subsurface Damage ◽  
Magnetorheological Finishing ◽  
Optical Glasses ◽  
Material Surfaces ◽  
Finishing Process ◽  
Deformed Layer

Magnetorheological finishing (MRF) is a precision optical finishing process traditionally limited to processing only nonmagnetic materials, e.g., optical glasses, ceramics, polymers, and metals. Here we demonstrate that MRF can be used for material removal from magnetic material surfaces. Our approach is to place an MRF spot on machined surfaces of magnetic WC-Co materials. The resulting surface roughness is comparable to that produced on nonmagnetic materials. This spotting technique may be used to evaluate the depth of subsurface damage, or deformed layer, induced by earlier manufacturing steps, such as grinding and lapping.

Experimental investigation and modelling of light scattering in a-Si:H solar cells deposited on glass/ZnO:Al substrates

2002 ◽  
Vol 715 ◽  
Author(s):  
J. Krc ◽  
M. Zeman ◽  
O. Kluth ◽  
F. Smole ◽  
M. Topic
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Solar Cells ◽  
Angular Distribution ◽  
Light Scattering ◽  
Optical Model ◽  
Distribution Functions ◽  
Interface Roughness ◽  
Scattering Parameters ◽  
Good Agreement

AbstractThe descriptive scattering parameters, haze and angular distribution functions of textured ZnO:Al transparent conductive oxides with different surface roughness are measured. An approach to determine the scattering parameters of all internal interfaces in p-i-n a-Si:H solar cells deposited on the glass/ZnO:Al substrates is presented. Using the determined scattering parameters as the input parameters of the optical model, a good agreement between the measured and simulated quantum efficiencies of the p-i-n a-Si:H solar cells with different interface roughness is achieved.

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