Magnetorheological Nano-Surface-Finishing of Tapered Cavity of Chrome Steel Punch

2019 ◽  
Author(s):  
Arpit Thomas ◽  
Anant Kumar Singh
Keyword(s):  
Surface Finish ◽  
Traditional Method ◽  
Flat Surface ◽  
Adhesive Wear ◽  
Surface Finishing ◽  
Chrome Steel ◽  
Micro Cracks ◽  
Finishing Process ◽  
Tapered Cavity ◽  
Direction Opposite

Abstract The need for finishing chrome steel punch has drastically increased in order to obtain products with high quality and productivity. Chrome steel finds its application in manufacturing of punch and dies because of its higher hardness as varies up to 62 HRC. The paper is focused on improving the productivity of chrome steel punch through improving the surface finish using magnetorheological finishing process with a solid rotating tool core. The traditional method used for finishing of the chrome steel punch involves diamond lapping where machining marks and surface micro cracks are observed. In punching operation, the punch undergoes adhesive wear which can be controlled if the surface finish of the punch is improved. The surface finish obtained after diamond lapping process is up to 408 nm range. In present work, the further finishing of the tapered cavity of chrome steel punch is carried out. The chrome steel punch workpiece is rotated in a direction opposite to the rotation of the tapered tool tip surface in order to efficiently perform the finishing operation. The final surface roughness value of the flat surface of circular tapered punch is obtained as 26 nm from 420nm while the roughness value of the tapered surface is obtained as 22 nm from 408 nm in 90 minutes of finishing.

Effect of Electrolyte on the Surface Smoothness Obtained by Electropolishing of Stainless Steel

2012 ◽  
Vol 713 ◽  
pp. 55-60 ◽  
Author(s):  
M. Hernando ◽  
Pedro Jose Núñez López ◽  
Eustaquio García Plaza ◽  
R. Trujillo
Keyword(s):  
Stainless Steel ◽  
Surface Finish ◽  
Chromic Acid ◽  
Bath Temperature ◽  
Surface Finishing ◽  
Initial Surface ◽  
Surface Finishes ◽  
Finishing Process ◽  
Steel Aisi ◽  
Stainless Steel Aisi

Electropolishing is a surface finishing process of metals and alloys that enhances brilliant surface finishes with low surface roughness values. The most widely used electrolytes for the electropolishing of stainless steel are varying concentrations of phosphoric and sulphuric acid, and occasionally additives such as chromic acid. The objective of this study was to assess the performance of three commonly used industrial electrolytes in terms of the surface finish of electropolished stainless steel AISI 316L. Each electrolyte had varying sulphuric-phosphoric acid combinations with or without chromic acid. The following electropolishing conditions were assessed: current density, bath temperature, electropolishing time, and initial surface texture. The results revealed that adding chromic acid to the electrolyte did not significantly enhance surface finish, and electropolishing ranges were quite similar for all three electrolytes.

Design and Development of Magnetorheological Fluid Machine for Flat Surface Finish

2020 ◽  
Vol 1013 ◽  
pp. 27-32
Author(s):  
Odwa Myataza ◽  
Khaled Abou-El-Hossein
Keyword(s):  
Magnetic Field ◽  
Surface Finish ◽  
Flat Surface ◽  
Low Cost ◽  
Magnetorheological Fluid ◽  
Surface Finishing ◽  
Design And Development ◽  
Mr Fluid ◽  
Motion System ◽  
Cnc Router

Surface finishing of glass and ceramics flats is difficult to perform using already existing traditional processes because of the brittle nature of these materials. In order to make traditional processes be able to accommodate these materials, relatively expensive aiding devices and approaches are required. The newly developed magnetorheological (MR) fluid finishing offers a solution to this problem at a relatively low cost. Magnetorheological fluids have been used in mechanical engineering applications because of the rheological behavior they possess under a magnetic field which enables the manipulation and pressure of loose abrasives on the machined surfaces and perform cutting action. This paper describes the design and development of an MR fluid machine-tool for flat surface finishing. The design presented herewith includes the design of the mechanical aspects of the ball-end tool machine and its support structure for a three-axis motion system. The objective of this study is realized based on utilizing a magnetic field, magnetorheological fluid and CNC router design to perform flat surface finishing.

Improved Fatigue Life Cycle Using Surface Finish and Surface Coating in a Cam-Roller System: Multi-Scale System Analysis and Verification

2005 ◽  
Author(s):  
D. Y. Hua ◽  
K. Farhang ◽  
L. E. Seitzman
Keyword(s):  
Fatigue Life ◽  
Contact Stress ◽  
Surface Finish ◽  
Combined Treatment ◽  
Surface Finishing ◽  
Finishing Process ◽  
Macro Scale ◽  
Subsurface Stress ◽  
Roller System ◽  
The Impact

Surface failure in the form of pitting wear is encountered in cam-roller systems. The failure appears to be initiated at micron-scale subsurface region. High stress is a result of the macro-scale requirement on the cam-roller motion event that produces high contact loads due to inertia of the roller and its follower link. Sliding of the roller and its impact onto the cam surface further compounds the detrimental effect of contact load. While conventionally a Hertz contact stress analysis can be used in ascertaining contact stress and maximum subsurface von Mises stress, it generally underestimates the stress when compared to the micron-scale subsurface stresses due to the presence of surface roughness. Contact analyses of cam and roller with rough surfaces are performed to examine the effects of two surface treatments. These involve surface finishing process in which a surface is rendered smooth, and the addition of a coating to the roller surface. Measurements of such cam and roller surfaces are used in micro-contact analysis module of Surface Distress Analytical Toolkit (SDAT) to examine the effect of surface finish and coating on maximum subsurface stress. It is found that smooth surface provides a 53% reduction in maximum subsurface stress. The analysis also shows that the addition of coating reduces subsurface stress nearly 7%. The impact of the combined treatment of the surface is an increase in fatigue life of the cam-roller system by nearly two orders of magnitude. The above findings are based on laboratory tests using six rollers without and with various degrees of finishing processes, and with and without addition of coating to the surfaces. Examination of the rollers indicates a general improvement in roller performance due to addition of coating. Most notably, the combination of finishing process and coating was found to provide the best fatigue life since the corresponding rollers showed no observable wear even after testing for 2161 hours, or the same number of cycles accumulated over about 500,000 truck miles.

Experimental investigations on finishing of a brass specimen by magneto-rheological honing technique

2021 ◽  
pp. 251659842110157
Author(s):  
Chinu Kumari ◽  
Sanjay Kumar Chak
Keyword(s):  
Magnetic Field ◽  
Process Parameters ◽  
Surface Finish ◽  
Rotational Speed ◽  
Field Application ◽  
Surface Finishing ◽  
Experimental Investigations ◽  
Significant Parameter ◽  
Magnetizing Current ◽  
Magneto Rheological

Magneto-rheological abrasive honing (MRAH) is an unconventional surface finishing technique that relies on abrasives mixed with a unique finishing fluid, which changes its characteristics on magnetic field application. This process imparts nanometric-level surface finish with a significant amount of uniformity. Rotating motion of the workpiece and continuous reciprocation of the finishing fluid in the MRAH process are recognized as the major aspects for adopting this process in finishing non-magnetic materials. The finishing obtained through the MRAH process relies on the workpiece’s material properties and process parameters such as concentration of abrasives in finishing fluid, rotational speed of the workpiece, and magnetic field strength/magnetizing current. To study the efficacy of MRAH process, a parametric study was conducted by performing few experiments on a brass workpiece. Design of experiment approach was adopted to plan the experiments, and the effect of different values of magnetizing current, the concentration of abrasives, and rotational speed on the surface finish were analyzed through the application of analysis of variance (ANOVA). From ANOVA, the rotational speed was found as the most significant parameter with a contribution of 48.90% on % reduction in roughness value (%∇Ra). Around 57% of roughness reduction was obtained at the optimized value of process parameters.

scholarly journals Gold, Silver, and Electrum Electroless Plating on Additively Manufactured Laser Powder-Bed Fusion AlSi10Mg Parts: A Review

Coatings ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 422
Author(s):  
Dana Ashkenazi ◽  
Alexandra Inberg ◽  
Yosi Shacham-Diamand ◽  
Adin Stern
Keyword(s):  
Additive Manufacturing ◽  
Low Cost ◽  
Ion Beam ◽  
Surface Finishing ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Finishing Process ◽  
Gold Silver ◽  
3D Printed

Additive manufacturing (AM) revolutionary technologies open new opportunities and challenges. They allow low-cost manufacturing of parts with complex geometries and short time-to-market of products that can be exclusively customized. Additive manufactured parts often need post-printing surface modification. This study aims to review novel environmental-friendly surface finishing process of 3D-printed AlSi10Mg parts by electroless deposition of gold, silver, and gold–silver alloy (e.g., electrum) and to propose a full process methodology suitable for effective metallization. This deposition technique is simple and low cost method, allowing the metallization of both conductive and insulating materials. The AlSi10Mg parts were produced by the additive manufacturing laser powder bed fusion (AM-LPBF) process. Gold, silver, and their alloys were chosen as coatings due to their esthetic appearance, good corrosion resistance, and excellent electrical and thermal conductivity. The metals were deposited on 3D-printed disk-shaped specimens at 80 and 90 °C using a dedicated surface activation method where special functionalization of the printed AlSi10Mg was performed to assure a uniform catalytic surface yielding a good adhesion of the deposited metal to the substrate. Various methods were used to examine the coating quality, including light microscopy, optical profilometry, XRD, X-ray fluorescence, SEM–energy-dispersive spectroscopy (EDS), focused ion beam (FIB)-SEM, and XPS analyses. The results indicate that the developed coatings yield satisfactory quality, and the suggested surface finishing process can be used for many AM products and applications.

Colour stability of surface finishes on thermally modified beech wood

2021 ◽  
Vol 114 ◽  
pp. 116-124
Author(s):  
Gabriela Slabejová ◽  
MÁRIA ŠMIDRIAKOVÁ
Keyword(s):  
Surface Finish ◽  
Beech Wood ◽  
Surface Finishing ◽  
Colour Stability ◽  
Colour Difference ◽  
Surface Finishes ◽  
Before And After ◽  
Thermally Modified Wood ◽  
Wood Surfaces ◽  
Modified Wood

Colour stability of surface finishes on thermally modified beech wood. The paper deals with the influence of the type of transparent surface finish on the change of colour of the surfaces of native beech wood and thermally modified wood. At the same time, the colour stability of three surface finishes on the surfaces of native and thermally modified beech wood was monitored. Beech wood was thermally modified at temperature of 125 °C for 6 hours. The thermal treatment was performed in a pressure autoclave APDZ 240, by the company Sundermann s.r.o in Banská Štiavnica. Three various types of surface finishes (synthetic, wax-oil, water-based) were applied onto the wood surfaces. The colour of the surfaces of native wood and thermally modified wood was measured in the system CIELab before and after surface finishing; the coordinates L*, a*, b*, C*ab and h*ab were measured. From the coordinates measured before and after surface finishing, the differences were calculated and then the colour difference ∆E* was calculated. Subsequently, the test specimens with the surface finishes were exposed to natural sunlight, behind glass in the interior for 60 days. The surface colour was measured at specified time of the exposure (10, 20, 30, 60 days). The results showed that the colour of the wood surfaces changed after application of the individual surface finishes; and the colour difference reached a change visible with a medium quality filter up to a high colour difference. The wax-oil surface finish caused a high colour difference on native wood and on thermally modified wood as well. On native beech wood, the lowest colour difference after exposure to sunlight was noticeable on the synthetic surface finish. On the surface of wood thermally modified, after exposure to sunlight, the lowest colour difference was noticeable on the surface with no surface finish.

scholarly journals Investigation into Hand Scraping: A Microanalysis

2018 ◽  
Vol 2 (4) ◽  
pp. 76 ◽  
Author(s):  
Kai Oßwald ◽  
Ingo Lochmahr ◽  
Yasin Bagci ◽  
Peter Saile
Keyword(s):  
Inertial Measurement Unit ◽  
Three Dimensional ◽  
Movement Pattern ◽  
Measurement Unit ◽  
Surface Finishing ◽  
Future Research ◽  
Tool Orientation ◽  
Inertial Measurement ◽  
Finishing Process ◽  
Basic Characteristics

Hand scraping is a manual surface finishing process that, despite its low productivity and high cost, is still applied in many industries because of its advantages concerning accuracy and tribology. In the presented microanalysis forces, movement patterns and tool orientation of individual hand scraping strokes were measured using a test stand, specifically designed for this purpose. It utilizes a camera, a three dimensional dynamometer, and an inertial measurement unit (IMU). The results show the basic characteristics of hand scraping. Typical courses of relevant quantities like cutting force, passive force, clearance, and directional angle are shown. In addition, the movement pattern of the tool during individual scraping strokes is analyzed. This research aims to contribute to a later implementation of automated scraping. The conducted research creates a base for future research regarding different scraping methods and achieved results.

scholarly journals Predictive Models of Double-Vibropolishing in Bowl System Using Artificial Intelligence Methods

2019 ◽  
Vol 3 (1) ◽  
pp. 27
Author(s):  
Joselito Alcaraz ◽  
Kunal Ahluwalia ◽  
Swee-Hock Yeo
Keyword(s):  
Surface Roughness ◽  
Predictive Modelling ◽  
Surface Finishing ◽  
Configuration Model ◽  
Percentage Error ◽  
Vibratory Finishing ◽  
Exponential Regression ◽  
Finishing Process ◽  
Family Of Curves ◽  
Exponential Regression Model

Vibratory finishing is a versatile and efficient surface finishing process widely used to finish components of various functionalities. Research efforts were focused in fundamental understanding of the process through analytical solutions and simulations. On the other hand, predictive modelling of surface roughness using computational intelligence (CI) methods are emerging in recent years, though CI methods have not been extensively applied yet to a new vibratory finishing method called double-vibropolishing. In this study, multi-variable regression, artificial neural networks, and genetic programming models were designed and trained with experimental data obtained from subjecting rectangular Ti-6Al-4V test coupons to double vibropolishing in a bowl system configuration. Model selection was done by comparing the mean-absolute percentage error and r-squared values from both training and testing datasets. Exponential regression was determined as the best model for the bowl double-vibropolishing system studied with a Test MAPE score of 6.1% and a R-squared score of 0.99. A family of curves was generated using the exponential regression model as a potential tool in predicting surface roughness with time.

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