Finite Element Simulation of Plane Magnetic Abrasive Finishing

2006 ◽  
Author(s):  
Atul Khatri ◽  
Vinod Yadava
Keyword(s):  
Surface Roughness ◽  
Finite Element ◽  
Magnetic Potential ◽  
Experimental Results ◽  
Workpiece Surface ◽  
Magnetic Abrasive Finishing ◽  
Hard Materials ◽  
Element Simulation ◽  
Finishing Process ◽  
Abrasive Finishing

The final machining (or finishing) of precision parts with high accuracy level is making the application of abrasive finishing technologies increasingly important. Magnetic abrasive finishing (MAF) is a new advanced finishing process used for fine finishing of extremely hard materials. It is employed for finishing of metals and non-metals. This paper focuses on the modeling and simulation for the prediction of surface roughness in plane magnetic abrasive finishing. A finite element based model is developed to find the magnetic potential distribution in gap between tool and workpiece. Further, magnetic potential is used to evaluate machining pressure, material removal and finally surface roughness of the workpiece surface. The simulation results are confirmed compared with the experimental results available in the literature. The simulated workpiece surface roughness shows features which are similar in nature to the experimental results.

Control of Lay on Cobalt Chromium Alloy Finished Surfaces Using Magnetic Abrasive Finishing and Its Effect on Wettability

2014 ◽  
Vol 136 (3) ◽  
Author(s):  
Arthur A. Graziano ◽  
Vasishta Ganguly ◽  
Tony Schmitz ◽  
Hitomi Yamaguchi
Keyword(s):  
Surface Roughness ◽  
Deionized Water ◽  
Chromium Alloy ◽  
Cobalt Chromium ◽  
Magnetic Abrasive Finishing ◽  
Wetting Properties ◽  
Chromium Alloys ◽  
Finishing Process ◽  
Abrasive Finishing ◽  
Intermittent Cutting

Freeform surfaces, including the femoral components of knee prosthetics, present a significant challenge in manufacturing. The finishing process is often performed manually, which leads to surface finish variations. In the case of knee prosthetics, this can be a factor leading to accelerated wear of the polyethylene tibial component. The wear resistance of polyethylene components might be influenced by not only the roughness but also the lay of femoral component surfaces. This study applies magnetic abrasive finishing (MAF) for nanometer-scale finishing of cobalt chromium alloys, which are commonly used in knee prosthetics and other freeform components. Using flat disks as workpieces, this paper shows the dominant parameters for controlling the lay in MAF and demonstrates the feasibility of MAF to alter the lay while controlling the surface roughness. The manually finished disk surfaces (with roughness around 3 nm Sa), consisting of random cutting marks, were compared to MAF-produced surfaces (also with roughness around 3 nm Sa) with different lays. Tests using deionized water droplets show that the lay influences the wetting properties even if the surface roughness changes by no more than a nanometer. Surfaces with unidirectional cutting marks exhibit the least wettability, and increasing the cross-hatch angle in the MAF-produced surfaces increases the wettability. Surfaces consisting of short, intermittent cutting marks were the most wettable by deionized water.

The Research of NC Magnetic Abrasive Finishing for Mould Parting Surface

2008 ◽  
Vol 389-390 ◽  
pp. 199-204
Author(s):  
Wei Qiang Gao ◽  
L. Meng ◽  
Qiu Sheng Yan ◽  
J.H. Song ◽  
T.X. Qiu
Keyword(s):  
Effective Control ◽  
Magnetic Pole ◽  
Workpiece Surface ◽  
Magnetic Abrasive Finishing ◽  
Finishing Process ◽  
Abrasive Finishing ◽  
Feeding Speed ◽  
Polishing Tool ◽  
The Relationship

In this paper, a new kind of NC magnetic abrasive finishing method with meshy polishing track to grind the parting face of mould was presented, and a new simple polishing tool using permanent magnet was also developed. Using the magnetic polishing tool, 3D NC polishing experiments was conducted on 2D parting surfaces. Experimental results reveal the relationship between several main parameters (rotational speed of magnetic pole, working gap, feeding speed and number of polishing times) and surface roughness. This study is expected to be helpful to improve the efficiency of finishing process, reduce worker's labor intensity, realize the effective control of finishing process and obtain fine quality of workpiece surface.

MAGNETIC ABRASIVE FINISHING PROCESS — A PARAMETRIC ANALYSIS

2005 ◽  
Vol 04 (02) ◽  
pp. 131-150 ◽  
Author(s):  
S. C. JAYSWAL ◽  
V. K. JAIN ◽  
P. M. DIXIT
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Finite Element ◽  
Flux Density ◽  
Surface Quality ◽  
Real Life ◽  
Magnetic Abrasive Finishing ◽  
Abrasive Particles ◽  
Abrasive Finishing ◽  
The Magnetic Field

Magnetic Abrasive Finishing (MAF) is one of the non-conventional finishing processes, which produces a high level of surface quality and is primarily controlled by magnetic field. In MAF, workpiece is kept between the two poles (N and S) of a magnet. The working gap between the workpiece and the magnet is filled with magnetic abrasive particles. A magnetic abrasive flexible brush (MAFB) is formed, acting as a multipoint cutting tool, due to the effect of magnetic field in the working gap. This paper deals with theoretical investigations of the plane MAF process to know the effect of the process parameters on the surface quality produced. The magnetic field is simulated using finite element model of the process. The magnetic field is also measured experimentally to validate the theoretical results. A series of numerical experiments are performed using the finite element and surface roughness models of the process to study the effect of flux density, height of working gap, size of magnetic abrasive particles and slots (size and location) in the magnetic pole on the surface quality. Based on the results, it is concluded that surface roughness value (R max ) of the workpiece decreases with increase in flux density and size of magnetic abrasive particles. Surface roughness value (R max ) decreases with decrease in working gap. R max value also decreases when the magnet has a slot as compared to the magnet having no slot. Present study would help in understanding the effect of the various parameters on surface roughness value without doing a number of real-life experiments.

A Comprehensive Review on Magnetic Abrasive Finishing Process

2016 ◽  
Vol 18 ◽  
pp. 1-20 ◽  
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.

scholarly journals Development of a New Ultra-High-Precision Magnetic Abrasive Finishing for Wire Material Using a Rotating Magnetic Field

Materials ◽  
2019 ◽  
Vol 12 (2) ◽  
pp. 312 ◽  
Author(s):  
Lida Heng ◽  
Cheng Yin ◽  
Seok Han ◽  
Jun Song ◽  
Sang Mun
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
High Precision ◽  
Rotational Speed ◽  
Steel Wire ◽  
Rotating Magnetic Field ◽  
Magnetic Abrasive Finishing ◽  
Wire Material ◽  
Finishing Process ◽  
Abrasive Finishing

In this paper, we propose a new ultra-high-precision magnetic abrasive finishing method for wire material which is considered to be difficult with the existing finishing process. The processing method uses a rotating magnetic field system with unbonded magnetic abrasive type. It is believed that this process can efficiently perform the ultra-high-precision finishing for producing a smooth surface finish and removing a diameter of wire material. For such a processing improvement, the following parameters are considered; rotational speed of rotating magnetic field, vibration frequency of wire material, and unbonded magnetic abrasive grain size. In order to evaluate the performance of the new finishing process for the wire material, the American Iron and Steel Institute (AISI) 1085 steel wire was used as the wire workpiece. The experimental results showed that the original surface roughness of AISI 1085 steel wire was enhanced from 0.25 µm to 0.02 µm for 60 s at 800 rpm of rotational speed. Also, the performance of the removed diameter was excellent. As the result, a new ultra-high-precision magnetic abrasive finishing using a rotating magnetic field with unbonded magnetic abrasive type could be successfully adopted for improving the surface roughness and removing the diameter of AISI 1085 steel wire material.

scholarly journals Study on improving hole quality of 7075 aluminum alloy based on magnetic abrasive finishing

2020 ◽  
Vol 12 (6) ◽  
pp. 168781402093200
Author(s):  
Anyuan Jiao ◽  
Guofu Zhang ◽  
Binghong Liu ◽  
Weijun Liu
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Surface Finishing ◽  
7075 Aluminum Alloy ◽  
Magnetic Abrasive Finishing ◽  
Finishing Process ◽  
Abrasive Finishing ◽  
Inner Surface ◽  
Spinning Speed

Based on the mechanism of magnetic abrasive finishing, the 7075 aluminum alloy (Al7075) was used in the experimental study. In order to improve wall surface quality and to remove the edge burrs of the hole, a novel magnetic abrasive finishing process was proposed. First, the radial magnetizing pole for the inner surface finishing process was confirmed. The evaluation of magnet spinning speed, abrasive mesh, and abrasive filling amount on the diameter deviation of the hole and surface roughness of the inner wall was studied. According to the characteristics of magnetic abrasive finishing process, Taguchi’s method was used to carry out the test. Through the analysis of variance, the best process parameters were determined and verified. The inner surface roughness was further decreased and the surface morphology was more uniform after finishing process. Second, the edge burr removal process of the hole exit was also studied, and the geometry of the burrs was measured before and after the magnetic abrasive finishing process. The results show that the burrs were significantly removed and the burr removal efficiency was improved by 33.3% compared with the conventional magnetic abrasive finishing process. Finally, the improved magnetic abrasive finishing process is an effective method in improving finishing quality of the Al7075 holes.

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