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.

Investigation on the Improvement of Surface Quality by the Magnetic Plate-Assisted Magnetic Abrasive Finishing Process

2021 ◽  
Vol 1018 ◽  
pp. 111-116
Author(s):  
Yan Hua Zou ◽  
Hui Jun Xie
Keyword(s):  
Magnetic Field ◽  
Surface Quality ◽  
Field Distribution ◽  
Magnetic Field Distribution ◽  
Magnetic Flux Density ◽  
Magnetic Pole ◽  
Magnetic Abrasive Finishing ◽  
Abrasive Finishing ◽  
Glass Lens ◽  
The Magnetic Field

The traditional magnetic abrasive finishing (MAF) process, the magnetic flux density at the bottom of the magnetic pole is unevenly distributed, resulting in poor uniformity of the finished surface. Therefore, it is proposed to improve the surface quality by attaching a magnetic plate at the bottom of the workpiece to improve the magnetic field distribution. It is confirmed by simulation that the magnetic field distribution at the bottom of the magnetic pole is effectively improved after the magnetic plate is attached. It is proved through experiments that the magnetic plate-assisted MAF process can obtain a smoother surface. The experimental results show that the surface roughness of the glass lens improves from 246 nm Ra to 3 nm Ra through the magnetic plate-assisted MAF process within 45min.

scholarly journals Evaluation of Parameters Affecting Magnetic Abrasive Finishing on Concave Freeform Surface of Al Alloy via RSM Method

2016 ◽  
Vol 2016 ◽  
pp. 1-14 ◽  
Author(s):  
Mehrdad Vahdati ◽  
SeyedAlireza Rasouli
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Freeform Surface ◽  
Al Alloy ◽  
Regression Equations ◽  
Magnetic Abrasive Finishing ◽  
Abrasive Finishing ◽  
The Impact ◽  
Abrasive Process ◽  
The Magnetic Field

The attempts of researchers in industries to obtain accurate and high quality surfaces led to the invention of new methods of finishing. Magnetic abrasive finishing (MAF) is a relatively new type of finishing in which the magnetic field is used to control the abrasive tools. Applications such as the surface of molds are ones of the parts which require very high surface smoothness. Usually this type of parts has freeform surface. In this study, the effect of magnetic abrasive process parameters on freeform surfaces of parts made of aluminum is examined. This method is obtained through combination of magnetic abrasive process and Control Numerical Computer (CNC). The use of simple hemisphere for installation on the flat area of the magnets as well as magnets’ spark in curve form is a measure done during testing the experiments. The design of experiments is based on response surface methodology. The gap, the rotational speed of the spindle, and the feed rate are found influential and regression equations governing the process are also determined. The impact of intensity of the magnetic field is obtained using the finite element software of Maxwell. Results show that in concave areas of the surface, generally speaking, the surface roughness decreases to 0.2 μm from its initial 1.3 μm roughness. However, in some points the lowest surface roughness of 0.08 μm was measured.

scholarly journals Effect of abrasive particle morphology along with other influencing parameters in magnetic abrasive finishing process

2021 ◽  
Vol 22 ◽  
pp. 15
Author(s):  
Farshid Ahmadi ◽  
Hassan Beiramlou ◽  
Pouria Yazdi
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Abrasive Particle ◽  
Particle Morphology ◽  
Orthopedic Implants ◽  
Spherical Particles ◽  
Machining Time ◽  
Magnetic Abrasive Finishing ◽  
Abrasive Particles ◽  
Abrasive Finishing

Surface characteristics play a very important role in medical implants and among surface features, surface roughness is very effective in some medical applications. Among the various methods used to improve surface roughness, magnetic abrasive finishing (MAF) process has been widely used in medical engineering. In this study, the effect of abrasive particle morphology along with four other process parameters, including type of work metal, finishing time, speed of finishing operation, and the type of abrasive powder were experimentally evaluated. Full factorial technique was used for design of experiment. Three commonly used metals in orthopedic implants i.e., Ti-6Al-4V alloy, AZ31 alloy and austenitic stainless-steel 316LVM, were selected for this study. Also, two types of magnetic abrasive particles with different shapes (spherical and rod-shaped) were considered in the experiments. The results of the experiments indicated that the morphology of the abrasive particles and the finishing time had the greatest effect on surface roughness and using rod-shaped abrasive particles resulted in better surface quality comparing to the spherical particles. Besides, the surface quality of steel 316LVM after MAF was the best among the other examined metals. Interaction plots of ANOVA also showed that interactions of material with morphology of abrasive particles, and material with machining time were found to be reasonably significant.

scholarly journals Development the Flexible Magnetic Abrasive Finishing Process by Transmitting the Magnetic Fields

2021 ◽  
Author(s):  
abbas moghanizadeh
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Magnetic Fields ◽  
Electric Current ◽  
Free Form ◽  
Process Time ◽  
Magnetic Abrasive Finishing ◽  
Abrasive Particles ◽  
Abrasive Finishing ◽  
Free Form Surface

Abstract The objective of this research is to present a novel approach in magnetic abrasive finishing to improve its potential for creating different finishing patterns in free-form surface using no special fixtures or tool machines to minimize the complexity of the process. The key point of this idea is that magnetic abrasive particles can move in especial patterns by transfer magnetic fields (similar a magnetic train moving on a magnetic rail) and create the desired polishing patterns on the surface simultaneously. The coils are placed under a thin plate, then a flexible magnetic path is created by a special arrangement of magnetic coils, after that, the coils are turned on and off in turn, and the magnetic abrasive particles move in the created path and abrasive the surface. The continuous movement of magnetic abrasive particles under the magnetic field will lead to abrasive the surface of thin sheets. The tests were performed on copper sheets with a thickness of 1 mm. Experimental parameters include electric current (0.25, 0.5, and 0.75A), speed of turning on and off of the coils (speed of magnetic abrasive particle movement) (20, 30, and 40 mm/s), and process time (1, 2, and 3 hours). The experiments were performed on an L-shaped and free-form sheets. The results show that using a transmission magnetic field in the MAF (TMAF) makes it easy to create different surface roughness patterns in different directions simultaneously. While in one part of the L shape the electric current is 0.25A, the surface roughness of is around 0.9 µm, in the other part, where the electric current is 0.75A, the surface roughness of is around 0.55 µm. Meanwhile, TMAF makes it possible to finish a free-form surface with no special fixtures. Moreover, there is a direct relationship between the change in the surface roughness and the electric current and process time.

scholarly journals Finite Element Analysis of the Magnetic Field Distribution in a Magnetic Abrasive Finishing Station and its Impact on the Effects of Finishing Stainless Steel AISI 304L

Metals ◽  
2021 ◽  
Vol 11 (2) ◽  
pp. 194
Author(s):  
Michał Marczak ◽  
Józef Zawora
Keyword(s):  
Finite Element ◽  
Magnetic Flux ◽  
Flux Density ◽  
Magnetic Flux Density ◽  
Regression Equations ◽  
Element Analysis ◽  
Aisi 304L ◽  
Magnetic Abrasive Finishing ◽  
The Real ◽  
Abrasive Finishing

In this article, we present a numerical model of a magnetic abrasive finishing station, which was analyzed using the finite element method (FEM). The obtained results were compared with the real values measured on an experimental station of our own design. The prepared station had the option of adjusting the magnetic flux density inside the machining gap, the width of which could be changed from 10 to 30 mm. The maximum value of the magnetic flux density inside the air gap was 0.8 T. The real distribution of magnetic flux density in the finishing area was also analyzed. A design of experiment was carried out with the following variables: abrasive grain concentration, width of the machining gap, and process duration. The results are presented in the form of regression equations and characteristics for selected roughness parameters.

Experimental Study on Mechanism and Performance of Magnetic Abrasive Finishing

2006 ◽  
Vol 304-305 ◽  
pp. 384-388
Author(s):  
Shu Ren Zhang ◽  
W.N. Liu
Keyword(s):  
Surface Roughness ◽  
Magnetic Force ◽  
Ferromagnetic Materials ◽  
Feed Speed ◽  
Magnetic Abrasive Finishing ◽  
Abrasive Particles ◽  
Technical Parameters ◽  
Abrasive Finishing ◽  
Series Of Experiments ◽  
And Performance

Magnetic Abrasive Finishing (MAF) is relatively a new finishing technique that employs the magnetic force for finishing. In the paper, finishing mechanism of MAF is studied and four self-sharpening modes of abrasive particles are put forward. With the cylindrical magnetic abrasive apparatus designed and made by the author, a series of experiments on finishing the cylindrical surfaces of nonferromagnetic materials and ferromagnetic materials are carried out. The influence of technical parameters (finishing speed, feed speed, finishing time and so on) on finishing performance is analyzed. Choosing the optimized technical parameters, , the surface roughness of ferromagnetic materials changes from Ra 0.825µm to Ra 0.045µm after the 12-minute finishing experiment; the surface roughness of nonferromagnetic materials changes from Ra 0.434µm to Ra 0.096µm after the 20-minute finishing experiment.

Experimental Study on Increasing Magnetic Abrasive Finishing Efficiency of Finishing Nonferromagnetic Materials

2007 ◽  
Vol 359-360 ◽  
pp. 300-304
Author(s):  
Shu Ren Zhang ◽  
Li Feng Yang ◽  
Guo Xiang Wu
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Magnetic Force ◽  
Magnetic Flux Density ◽  
Experimental Conditions ◽  
Magnetic Abrasive Finishing ◽  
Abrasive Particles ◽  
Abrasive Finishing ◽  
Series Of Experiments ◽  
Diameter Reduction

Magnetic Abrasive Finishing (MAF) is relatively a new finishing technique which employs the magnetic force for finishing. In this paper, the influence of the magnetic flux density on the finishing pressure and the finishing efficiency during finishing is analyzed. With the cylindrical magnetic finishing apparatus developed by the author, a series of experiments on finishing the cylindrical surfaces of nonferromagnetic materials and ferromagnetic materials are carried out. To solve the problems of low finishing efficiency and abrasive particles escaping easily because of lack of finishing pressure during finishing nonferromagnetic materials, a new method of increasing the finishing pressure by using the “pressure-increasing bag” in the finishing system is put forward. A lot of comparative experiments on finishing nonferromagnetic materials with the “pressure-increasing bag” and without the “pressure-increasing bag” are performed. Under the same experimental conditions, the amount of diameter-reduction d is increased from 1μm to 1.88μm and the surface roughness is improved from Ra0.315μm to Ra0.250μm by using the “pressure-increasing bag”. The results show that the finishing pressure is increased obviously and the MAF efficiency of finishing nonferromagnetic materials is improved dramatically by using the “pressure-increasing bag”.

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 Interplay of Process Variables in Magnetic Abrasive Finishing of AISI 1018 Steel Using SiC and Al2O3 Abrasives

2019 ◽  
Vol 3 (2) ◽  
pp. 29 ◽  
Author(s):  
Mohammad Uddin ◽  
Vincent Santos ◽  
Romeo Marian
Keyword(s):  
Surface Quality ◽  
Process Parameters ◽  
Rotational Speed ◽  
Mesh Size ◽  
Magnetic Abrasive Finishing ◽  
Abrasive Particles ◽  
Abrasive Finishing ◽  
Type Size ◽  
Dominant Process ◽  
Series Of Experiments

This paper investigates the underlying interplay between the key process parameters of magnetic abrasive finishing (MAF) in improving surface quality. The five process parameters considered were the working gap, rotational speed, feed rate, abrasive amount, and abrasive mesh when MAFed independently with two abrasive particles—SiC and Al2O3. A series of experiments were conducted with an in-house built MAF tool. Based on the main effect results, a model predicting roughness reduction was developed. Results show that surface quality improvement and the underlying dominant process parameters seem unique to the abrasive type used. When MAFed with SiC, the abrasive quantity and rotational speed influence the most. On the other hand, when MAFed with Al2O3, the trend is different to SiC, i.e., the abrasive mesh size and the working gap are dominant. The prediction model was well validated by independent experiments, indicating its accuracy in estimating and optimizing the process outcome. MAF is a simple process with a complex interplay between parameters. This is very crucial when abrasive type, size, and amount to be used are concerned, which warrants a deeper investigation in terms of underlying dynamics, interactions, and the deformation of abrasive, magnetic, and workpiece materials.

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.

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