Experimental Investigations Into the Finishing Force and Torque in Magnetic Abrasive Finishing Process

2013 ◽  
Author(s):  
R. S. Mulik ◽  
P. M. Pandey
Keyword(s):  
Supply Voltage ◽  
Research Work ◽  
Experimental Investigations ◽  
Magnetic Abrasive Finishing ◽  
Factors Affecting ◽  
Weight Percentage ◽  
Finishing Process ◽  
Abrasive Finishing ◽  
Sem Study ◽  
Four Levels

Magnetic abrasive finishing (MAF) is a finishing process in which surface is finished by removing the material in the form of micro-chips by the magnetic and abrasive particles in the presence of a magnetic field. In a finishing process, forces have direct influence on the generation of finished surface and accuracy of the workpiece. The magnitude of force or torque is also of importance as the surface integrity is affected. In the present research work, new design of electromagnet which gave relatively lesser force and torque as compared to conventional annular electromagnet was used to perform MAF. The measurements of normal force and finishing torque were carried out at different processing conditions using Kistler’s dynamometer and were found in the order of 24 N and 8 Nm respectively. The experiments were planned using Taguchi’s L16 orthogonal array and supply voltage to electromagnet, rpm of electromagnet, finishing gap and abrasive weight percentage at four levels were considered as process parameters. Supply voltage to the electromagnet and finishing gap were found to be the significant factors affecting finishing force and torque in this work. The scanning electron microscopy (SEM) study of the finished workpiece showed that there was no surface or subsurface damage due to very low finishing force and torque.

Experimental Investigations and Modeling of Finishing Force and Torque in Ultrasonic Assisted Magnetic Abrasive Finishing

2012 ◽  
Vol 134 (5) ◽  
Author(s):  
Rahul S. Mulik ◽  
Pulak M. Pandey
Keyword(s):  
Mathematical Models ◽  
Normal Force ◽  
Supply Voltage ◽  
Experimental Investigations ◽  
Magnetic Abrasive Finishing ◽  
Factors Affecting ◽  
Finishing Process ◽  
Abrasive Finishing ◽  
Ultrasonic Assisted ◽  
Good Agreement

An ultrasonic assisted magnetic abrasive finishing (UAMAF) process uses an ultrasonic vibrations and magnetic abrasive finishing (MAF) process. In a finishing process there are two types of forces that act during the finishing of the workpiece by UAMAF, namely, normal force and cutting force. The finishing forces have direct influence on the generation of the finished surface and accuracy of the workpiece. Therefore, in the present work, normal force and finishing torque have been measured at various processing conditions during UAMAF. Supply voltage to the electromagnet and finishing gap have been found to be the significant factors affecting the finishing forces and torque. Mathematical models based on process physics have been developed to predict the finishing force and torque. The developed models predict force and torque as a function of supply voltage, machining gap, and workpiece hardness. The developed mathematical models for normal force and finishing torque have been validated and were found to be in good agreement with experimental results.

Experimental investigations into ultrasonic-assisted double-disk magnetic abrasive finishing of two paramagnetic materials

2015 ◽  
Vol 231 (6) ◽  
pp. 1021-1038 ◽  
Author(s):  
Prateek Kala ◽  
Pulak M Pandey
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Experimental Investigations ◽  
Magnetic Abrasive Finishing ◽  
Force Microscopy ◽  
Finishing Process ◽  
Abrasive Finishing ◽  
Ultrasonic Assisted ◽  
Paramagnetic Materials ◽  
Pulse On Time

This article evaluates the finishing performance of ultrasonic-assisted double-disk magnetic abrasive finishing process on two paramagnetic materials (copper alloy and stainless steel) with different mechanical properties such as flow stress, hardness, shear modulus, and so on. The finishing experiments were performed based on response surface methodology. The results obtained after finishing have been analyzed to determine the effect of different process parameters such as working gap, rotational speed, and pulse-on time of ultrasonic vibration for both work materials and to study various interaction effects that may significantly affect the finishing performance by the process. The outcome of analysis for the two different work materials has been critically compared to understand the effect of the considered process parameters on the finishing performance of the process based on mechanical properties of the workpiece such as hardness. Furthermore, the scanning electron microscopy and atomic force microscopy were carried on the workpiece surface to understand the possible mechanism of material removal and the surface morphology produced after the finishing process.

Factors Affecting the Finishing Characteristics of an Internal Magnetic Abrasive Finishing Process for High Purity Fittings

2004 ◽  
Author(s):  
Hitomi Yamaguchi ◽  
Takeo Shinmura ◽  
Megumi Sekine
Keyword(s):  
Magnetic Field ◽  
High Purity ◽  
Target Surface ◽  
Magnetic Abrasive Finishing ◽  
Factors Affecting ◽  
Shaped Tube ◽  
Finishing Process ◽  
Abrasive Finishing ◽  
Abrasive Behavior ◽  
The Magnetic Field

In the case of internal finishing of the bent section of a complex shaped tube, such as found in high purity fittings, by a magnetic abrasive finishing process, the magnetic field at the finishing area and, therefore, the finishing force are hardly uniform over the entire finishing area due to the geometry. This affects the abrasive behavior against the inner surface of the bent section, changing the finishing characteristics of SUS304 stainless steel fittings. In practice, non-uniformities in the surface finish remain at the bent section between the inside, outside, and lateral regions. This unevenness combines to cause difficulties in achieving uniform finishing. Magnetic abrasive is generally supplied with ferrous particles, and the ferrous particles experience greater magnetic force and play a role in pressing the magnetic abrasive against the target surface. This paper studies the finishing mechanism in view of the relationship between the magnetic field, the ferrous particles mixed with magnetic abrasive, and the finishing characteristics. The experiments identify the finishing conditions required for successfully diminishing the non-uniformity in the finished surface, and methods are recommended to satisfy the required conditions. The experiments using the proposed methods show the feasibility of producing a uniformly finished mirror surface.

scholarly journals COMPARATIVE ANALYSIS ON NUMERICAL MODELLING AND EXPERIMENTS OF THE CUTTING TEMPERATURE IN MAGNETIC ABRASIVE FINISHING PROCESS

2019 ◽  
Vol 19 (1) ◽  
pp. 1-13
Author(s):  
Dr. Ali H Kadhum
Keyword(s):  
Cutting Temperature ◽  
Experimental Tests ◽  
Cutting Parameters ◽  
Finite Element Models ◽  
Magnetic Abrasive Finishing ◽  
Finishing Process ◽  
Abrasive Finishing ◽  
Good Comparison ◽  
Dimensional Finite Element ◽  
Four Levels

In Magnetic Abrasive Finishing (MAF) process the cutting temperature is generated from two sources, from the electromagnetic flux (electrical heat), and from magnetic abrasive brush due to the friction force (mechanical heat). The cutting temperature has significant effects upon the condition of the surface, whereas it is less studied than the other parameters. In this study, an attempt has been made to simulate and investigate the influence of cutting parameters on the cutting temperature, to improve the thermal effect by MAF process. The aims of this study was to determine the distribution of the cutting temperature in the working gap, numerically and experimentally, then compared the results. In addition, to determine the most influence parameters affecting on the cutting temperature for Brass alloy CuZn28. Two dimensional Finite Element Models (FEM) with two software’s were developed to predict the temperature by dynamic electric and magnetic field, the first was DEFORM 10.2 used to calculate the mechanical heat and the second was COMSOL5.2 used to calculate the electrical heat. Sixteen tests designed according to Taguchi matrix through the orthogonal array (OA) L16 (). There are four various parameters that, have a large impact on cutting temperature, with four levels (rotational speed (A), working time (B), current (C), and working gap (D)). The analysis of the variance (ANOVA) technique was utilized to analysis the results, by using the statistical software (MINITAB-17). From the results, it is concluded that the Numerical modeling gives a very good comparison with the values of experimental tests. The maximum difference between the numerical and experimental temperature for brass CuZn28 is less than (9%).

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

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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