An Analysis of Polishing Forces in Magnetic Field Assisted Finishing

2012 ◽  
Author(s):  
Vasishta Ganguly ◽  
Tony Schmitz ◽  
Arthur A. Graziano ◽  
Hitomi Yamaguchi
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Iron Particle ◽  
Free Form ◽  
Work Piece ◽  
Total Force ◽  
Polishing Force ◽  
Strong Relation ◽  
Force Components ◽  
Free Form Surfaces

Magnetic field assisted finishing (MAF) is used to polish free-form surfaces. The material removal mechanism can be described as a flexible “magnetic brush” that consists of ferromagnetic particles and abrasives that arrange themselves in the working gap between the magnet and the work piece. Relative motion between the brush and the work piece causes micro-cutting and improves surface finish. In this study, the contributions of the magnetic and polishing force components to the total force were evaluated. The effect of varying the polishing conditions, such as the working gap and the size of the ferromagnetic iron particles, on polishing forces and surface roughness was also analyzed. It was observed that the polishing forces varied considerably with working gap. Also, the iron particle size was found to have a strong relation to the rate at which the surface roughness decreased. Surface area roughness of 2–3 nm was achieved.

Force Measurement and Analysis for Magnetic Field–Assisted Finishing

2013 ◽  
Vol 135 (4) ◽  
Author(s):  
Vasishta Ganguly ◽  
Tony Schmitz ◽  
Arthur Graziano ◽  
Hitomi Yamaguchi
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Material Removal ◽  
Force Measurement ◽  
Removal Rate ◽  
Iron Particle ◽  
Free Form ◽  
Total Force ◽  
Polishing Force ◽  
Free Form Surfaces

Magnetic field–assisted finishing (MAF) is used to polish free-form surfaces. The material removal mechanism can be described as a flexible “magnetic brush” that consists of ferromagnetic particles and abrasives that arrange themselves in the working gap between the magnet and the workpiece. Relative motion between the brush and the workpiece causes microcutting and improves surface finish. In this study, the contributions of the magnetic and polishing force components to the total force were evaluated. The effect of varying the polishing conditions, such as the working gap and the size of the ferromagnetic iron particles, on polishing forces, surface roughness, and material removal rate was also analyzed. It was observed that the polishing forces varied considerably with working gap. Also, the iron particle size was found to have a strong relation to the rate at which the surface roughness improved. Surface roughness values of 2–3 nm were achieved.

Study on the Fuzzy-PID Policy for Force Control in Free-Form Surfaces Polishing by Robots

2011 ◽  
Vol 101-102 ◽  
pp. 422-426
Author(s):  
Xiao Ling Su ◽  
Jian Ming Zhan
Keyword(s):  
Force Control ◽  
Normal Direction ◽  
Curved Surface ◽  
Free Form ◽  
Work Piece ◽  
Fuzzy Pid ◽  
Polishing Force ◽  
The Right ◽  
Free Form Surfaces ◽  
Polishing Tool

When a robot is used to polish or finish a curved surface, both feed movement and contact force have to be controlled at the same time so that the polishing tool would machine its work-piece at the right position in right posture with required force. In this paper, a passive wrist system is developed to adapt the shape of the machining curved surface by changing its posture along with the surface. And under the Fuzzy-PID policy, polishing force is controlled at a stable value in the normal direction of the named machining point while the polishing tool moving along the curved surface by multi-point machining. It means that the passive wrist system and the model of the surroundings could be used in force controlling when robots polish free-form surfaces with multi-point machining by a grinding ring.

Surface Quality Prediction in Case of Steep Free Form Surface Milling

2016 ◽  
Vol 686 ◽  
pp. 119-124 ◽  
Author(s):  
Balázs Mikó
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Tool Path ◽  
Complex Geometry ◽  
Cutting Parameters ◽  
Free Form ◽  
Milling Cutter ◽  
Good Surface ◽  
2.5D Milling ◽  
Free Form Surfaces

The machining of free form surfaces is a current and important issue in die and mould industry. Beside the complex geometry, an accurate and productive machining and good surface quality are needed. The finishing milling carried out by a ball-end or toroid milling cutter defines the surface quality, which is characterized by the surface roughness and the tool path trace. The surface quality is defined by the properties of the milling cutter, the type of surface and its position, as well as the cutting parameters. This article focuses on the z-level milling of steep surfaces by 2.5D milling strategy. The importance of the different elements of the tool path is presented, the effect of cutting parameters is investigated, and a formula to predict the surface roughness is suggested.

Effect of the Working Diameter to the Surface Quality in Free-Form Surface Milling

2013 ◽  
Vol 581 ◽  
pp. 372-377 ◽  
Author(s):  
Balázs Mikó ◽  
Jozef Beňo
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Cutting Speed ◽  
Chip Thickness ◽  
Free Form ◽  
Effective Diameter ◽  
Test Part ◽  
Free Form Surface ◽  
Free Form Surfaces

The article presents the changing of the working diameter (effective diameter) and its effect to the surface roughness based on milling experiments of a test part in 3D milling of free-form surfaces. The position of the surface and the step depth determine the effective diameter, in case of constant revolution of the tool, the actual cutting speed and the minimal removable chip thickness will change. The article presents the result of the application of the constant cutting speed and feed per tooth.

Study of Dynamic Magnetic Field Assisted Finishing for Metal Mold Using Magnetic Compound Fluid (MCF)

2010 ◽  
Vol 447-448 ◽  
pp. 258-262 ◽  
Author(s):  
Takashi Sato ◽  
Yong Bo Wu ◽  
Wei Min Lin ◽  
Kunio Shimada
Keyword(s):  
Magnetic Field ◽  
Three Dimensional ◽  
High Hardness ◽  
Cellulose Fiber ◽  
Free Form ◽  
Metal Mold ◽  
High Form ◽  
Three Dimensional Configuration ◽  
Free Form Surfaces ◽  
Dynamic Magnetic Field

The finishing process of a metal mold depends on the hand work of experts by using a whetstone tool in many cases. This is because it is difficult to treat the three-dimensional configuration, such as free-form surfaces and convex and concave configurations. To overcome this difficulty, we propose a dynamic magnetic field assisted finishing using magnetic compound fluid (MCF) for three-dimensional configurations. In this paper, we demonstrate the MCF slurry (MCF mixed abrasive and cellulose fiber in) under dynamic magnetic field shows the high form restoration and generates the high normal force compared to that under static magnetic field; resulting in shows the high finishing performance. Moreover, we compare and discuss the surface roughness and form accuracy under both static and dynamic magnetic fields against three-dimensional configuration made of high hardness non-ferrous mold steel HPM75, which is used for plastic injection mold.

Study on the Polishing Force of Face Polishing

2010 ◽  
Vol 37-38 ◽  
pp. 1340-1344
Author(s):  
Xiao Cun Xu ◽  
Yan Gang He ◽  
Yan Min Wang
Keyword(s):  
Physical Model ◽  
Process Parameters ◽  
State Of The Art ◽  
Friction Condition ◽  
Free Form ◽  
Polishing Process ◽  
Polishing Force ◽  
Almost All ◽  
Free Form Surfaces ◽  
Near Future

Since almost all large die surfaces are free-form surfaces, currently, these are mostlty manually polished. In order to overcome this barrier, floating face polishing is a feasible polishing technology. The polishing force is a key problem of floating polishing technology. This paper tries to study face polishing force on base of analyzing 3D polishing physical model. The paper focuses on the establishment of the model of face polishing force with full friction condition. The research results will be used for the development of a portable, state-of-the-art polishing machine and the optimization of the associated polishing process parameters in the near future.

Applications of Ultra-Precision Free-Form Machining Technology to Advanced Optics

2011 ◽  
Vol 697-698 ◽  
pp. 834-837
Author(s):  
Wing Bun Lee ◽  
H. Wang ◽  
Suet To ◽  
C.F. Cheung
Keyword(s):  
Surface Roughness ◽  
High Accuracy ◽  
Consumer Electronics ◽  
Free Form ◽  
Advanced Imaging ◽  
Ultra Precision ◽  
Commercial Applications ◽  
Free Form Surfaces

Nowadays, the proliferation of commercial applications of consumer electronics and advanced optics has imposed extensive requirements on the fabrication of non-conventional geometries and free-form surfaces with stringent achievable tolerances and extremely high accuracy and surface roughness. This paper exhibits our successful applications of ultra-precision free-form machining technology to the production of a variety of advanced imaging and illumination optics.

Development on Shape-Adaptive Compliant Tool System

2013 ◽  
Vol 433-435 ◽  
pp. 2164-2168
Author(s):  
Yun Chuan Zeng ◽  
Jian Ming Zhan ◽  
Yu Zhao
Keyword(s):  
Tool Path ◽  
Industrial Robots ◽  
Free Form ◽  
Main Principle ◽  
Rotating Sphere ◽  
Servo Mechanism ◽  
Polishing Force ◽  
Spring System ◽  
Five Axis ◽  
Free Form Surfaces

A new shape-adaptive compliant tool system is developed in this essay, which can be effectually integrated with industrial robots and five-axis NC machines. The main principle of the above compliant tool system can be described as follows: a passive servo mechanism of bi-directional rotating sphere hinge, working with the robots to control the tool-path which can meet the requirements of the adaptive capability on free-form surfaces. The normal polishing force could be controlled by the designed linear stepping motor and column helix spring system. The virtual prototyping of the tool system is created in ADAMS, and used to take the simulating experiments on workpieces which have typical free-form surfaces. The experimental results indicate that the tool system developed in this essay performs well on shape-adaptive capacity on free-form surfaces.

scholarly journals Optimization of Cutting Data and Tool Inclination Angles During Hard Milling with CBN Tools, Based on Force Predictions and Surface Roughness Measurements

Materials ◽  
2020 ◽  
Vol 13 (5) ◽  
pp. 1109 ◽  
Author(s):  
Andrzej Matras ◽  
Wojciech Zębala
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Machining Process ◽  
Free Form ◽  
Inclination Angles ◽  
Cutting Force Components ◽  
Force Components ◽  
Feed Rate Optimization ◽  
Roughness Measurements

This work deals with technological considerations required to optimize the cutting data and tool path pattern for finishing the milling of free-form surfaces made of steel in a hardened state. In terms of technological considerations, factors such as feed rate, workpiece geometry, tool inclination angles (lead and tilt angles) and surface roughness are taken into account. The proposed method is based on calculations of the cutting force components and surface roughness measurements. A case study presented in the paper is based on the AISI H13 steel, with hardness 50 HRC and milling with a cubic boron nitride (CBN) tool. The results of the research showed that by modifications of the feed value based on the currently machined cross-sectional area, it is possible to control the cutting force components and surface roughness. During the process optimization, the 9% and 15% increase in the machining process efficiency and the required surface roughness were obtained according to the tool inclination angle and feed rate optimization procedure, respectively.

scholarly journals The Effect of the Feed Direction on the Micro- and Macro Accuracy of 3D Ball-end Milling of Chromium-Molybdenum Alloy Steel

Materials ◽  
2019 ◽  
Vol 12 (24) ◽  
pp. 4038
Author(s):  
Balázs Mikó ◽  
Bálint Varga ◽  
Wojciech Zębala
Keyword(s):  
Surface Roughness ◽  
Metal Cutting ◽  
Tool Path ◽  
End Milling ◽  
Cutting Parameters ◽  
Machining Process ◽  
Free Form ◽  
Dimensional Error ◽  
Ball End Milling ◽  
Free Form Surfaces

The machining of free form surfaces is one of the most challenging problems in the field of metal cutting technology. The produced part and machining process should satisfy the working, accuracy, and financial requirements. The accuracy can describe dimensional, geometrical, and surface roughness parameters. In the current article, three of them are investigated in the case of the ball-end milling of a convex and concave cylindrical surface form 42CrMo4 steel alloy. The effect of the tool path direction is investigated and the other cutting parameters are constant. The surface roughness and the geometric error are measured by contact methods. Based on the results, the surface roughness, dimensional error, and the geometrical error mean different aspects of the accuracy, but they are not independent from each other. The investigated input parameters have a similar effect on them. The regression analyses result a very good liner regression for geometric errors and shows the importance of surface roughness.

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