Analysis of finishing performance in rotating magnetorheological honing process with the effect of particles motion

2021 ◽  
pp. 095440892199013
Author(s):  
Sunil K Paswan ◽  
Anant K Singh
Keyword(s):  
Surface Finish ◽  
Ground Surface ◽  
Internal Surface ◽  
Inside Surface ◽  
Scanning Electron Micrographs ◽  
Abrasive Particles ◽  
Finishing Process ◽  
Operation Results ◽  
Finishing Processes ◽  
Rotating Workpiece

The particles used in magnetorheological polishing (MRP) fluid are the key components of the magnetorheological (MR) finishing processes. The rotational magnetorheological honing (R-MRH) process is recently developed as a highly productive MR finishing process which is used for finishing the internal surface of the industrial cylindric components. The involvement of micron-sized abrasive particles of MRP fluid in the finishing operation results in the invisible observation of the finishing mechanism which enables the urge of analyzing the motion of the particles during the present R-MRH process. Therefore, the effect of motions of the MRP-fluid’s particles is analyzed for nano-finishing performance on the inside surface of the cylindric workpieces. The motions performed by active abrasive particles on the inside surface of the rotating hollow cylindric workpiece cause a higher finishing rate. The effects of particle motions on the reduction in surface roughness and improvement in surface morphology confirm the usefulness of the R-MRH process. The surface finish with the effect of the particles' motions of the MRP-fluid in the R-MRH process on the stationary workpiece’s inner surface is achieved upto 100 nm from 420 nm of the initial ground surface in 60 min of finishing. Whereas, the same aforementioned surface of the rotating workpiece is finished upto 50 nm from the same initial ground surface in only 40 min of finishing with the effect of the particles' motions of the MRP-fluid. The improvement in the surface finish is also noticed through the scanning electron micrographs in this work. The significant change in surface finish obtained in experimentations confirms the integrity of the analytical study conducted for understanding the effects of motions of particles while finishing with the R-MRH process.

Some Investigations Into Magnetorheological Finishing (MRF) of Hard Materials

2009 ◽  
Author(s):  
V. K. Jain ◽  
Pankaj Singh ◽  
Puneet Kumar ◽  
Ajay Sidpara ◽  
Manas Das ◽  
...  
Keyword(s):  
Surface Finish ◽  
Magnetorheological Finishing ◽  
Abrasive Particles ◽  
Hard Materials ◽  
Proposed Model ◽  
Finishing Process ◽  
Abrasive Finishing ◽  
Finishing Processes ◽  
Polishing Fluid ◽  
Magnetorheological Polishing Fluid

Magnetorheological finishing (MRF) process is one of the fine abrasive finishing processes used to get better surface finish on a semi finished part. The present work is aimed at investigating the effectiveness and validity of magnetorheological finishing process and finding out the process parameters (such as finishing time, rotational speed of carrier wheel, abrasive concentration, and working gap) and their effectiveness on surface finish characteristics. MRF process is applied on brass and nonmagnetic stainless steel workpieces which were initially finished by the grinding process. The results of experiments were statistically analyzed by response surface methodology (RSM) to form an empirical model for the responses generated during the process. Also, an attempt has been made to model and simulate the finishing operation in MRF process. Apart from this, the micro structure of the mixture of magnetic and abrasive particles in magnetorheological polishing fluid (MR Fluid) has been proposed. Thereafter the normal force on the abrasive particles is calculated from the applied magnetic field and a model for the prediction of surface roughness has also been presented. Finally, theoretical results calculated using the proposed model, have been compared with the experimental results to validate the model developed.

Development and Rheological Characterisation of Abrasive Flow Finishing Medium for Finishing Macro to Micro Features

2020 ◽  
Vol 70 (2) ◽  
pp. 190-196
Author(s):  
Sachin Singh ◽  
M. Ravi Sankar
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Recast Layer ◽  
Technological Advancement ◽  
Minimal Cost ◽  
Finishing Process ◽  
Fine Surface ◽  
Micro Features ◽  
Finishing Processes ◽  
Abrasive Flow Finishing

Technological advancement demands the manufacturing of components with a fine surface finish at a minimal cost. This scenario acts as the driving force for the research communities to develop economic finishing processes. Abrasive flow finishing (AFF) is one of the advanced finishing processes employed for finishing, deburring, radiusing and recast layer removal from the workpiece surfaces. AFF process uses a finishing medium that acts as a deformable tool during the finishing process. It is the rheological properties of the medium that profoundly influences the end surface finish obtained on the workpiece after the AFF process. In the current work, an attempt is made to develop an economic AFF medium by using viscoelastic polymers i.e., soft styrene and soft silicone polymer. Detailed static and dynamic characterisation of the medium is carried out. Later, to study the finishing performance of the developed medium, AFF experiments are performed for the finishing of macro and micro feature components. The experimental study showed that the nano surface finish could be achieved by varying the viscosity of the developed medium. Developed medium achieved 89.06 per cent improvement in surface roughness during finishing of tubes (macro feature component), while 92.13 per cent and 88.11 per cent surface roughness improvement is achieved during finishing of microslots and microholes (micro feature component), respectively.

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.

Evaluation of Rheological Properties of Magnetorheological Polishing Fluid and Their Effect on Surface Finish in Ultra Precision Finishing Processes

2005 ◽  
Author(s):  
Sunil Jha ◽  
V. K. Jain
Keyword(s):  
Particle Size ◽  
Rheological Properties ◽  
Surface Finish ◽  
Iron Particle ◽  
Abrasive Particles ◽  
Ultra Precision ◽  
Effect Of Particle Size ◽  
Finishing Processes ◽  
Polishing Fluid ◽  
Magnetorheological Polishing Fluid

Magnetorheological finishing (MRF) process for automated lens finishing and Magnetorheological abrasive flow finishing (MRAFF) for internal geometries rely on unique smart behavior of MRP-fluid. The rheological properties of MRP-fluid depend on carbonyl iron particle (CIP) and silicon carbide (SiC) particle size, their volume concentration, magnetic properties and applied magnetic field strength. To study the effect of particle size on rheological properties of MRP-fluid, a hydraulically driven specially designed capillary rheometer is fabricated. The best surface finish improvement was obtained with MRP-fluid containing approximately equal diameter of abrasive particles and CIPs. Least improvement was noticed with smaller CIPs and bigger abrasive combinations used. This is because the smaller size CIPs are incapable of providing the necessary finishing forces for bigger abrasive particles, which results in weak bonding strength.

Magnetorheological Finishing (MRF) of a Freeform Non-magnetic Work Material

2015 ◽  
Vol 15 (3) ◽  
pp. 249-256
Author(s):  
Laxmi Narayan Pattanaik ◽  
Himanshu Agarwal
Keyword(s):  
Surface Finish ◽  
Mesh Size ◽  
Magnetorheological Finishing ◽  
Mr Fluid ◽  
Abrasive Particles ◽  
Finishing Process ◽  
Set Up ◽  
Complicated Geometries ◽  
Flexible Magnetic Abrasive Brush ◽  
Precision Finishing

AbstractOne of the newly developed methods for obtaining super-finished shiny surfaces for non-magnetic freeform jobs is magnetorheological finishing (MRF). MRF is an advanced finishing process in which the grinding force is controlled by magnetic field. The material removal in MRF is governed by the magnetorheological (MR) fluid which mainly consists of carbonyl iron (CI), abrasive particles, carrier fluids and additives. It is a precision-finishing process that can finish complicated geometries or difficult-to-approach regions. MRF process is capable of giving nanometre-scale surface finish. The process makes use of an MR fluid as a tool that acts as a flexible magnetic abrasive brush that provides finishing action. The relative motion between the finishing medium and the work can be obtained either by rotating the work, rotating the finishing medium or both. In the present paper, a set-up has been developed for MRF application using a pillar-drilling machine. Experiments were conducted to finish freeform jobs of copper alloy using the developed process. The effects of various process parameters, viz composition of the MR fluid, rotational speed of work and vessel containing MR fluid, mesh size of abrasives on surface finish, were explored.

Modeling of surface roughness in the magnetorheological cylindrical finishing process

2017 ◽  
Vol 233 (1) ◽  
pp. 104-117 ◽  
Author(s):  
Vishwas Grover ◽  
Anant Kumar Singh
Keyword(s):  
Mathematical Model ◽  
Surface Roughness ◽  
Outer Surface ◽  
Internal Surface ◽  
Percentage Error ◽  
Abrasive Particles ◽  
Finishing Process ◽  
Inner Surface ◽  
Cylindrical Workpiece ◽  
Finishing Tool

The magnetorheological cylindrical finishing process is developed for fine finishing of the internal surface of cylindrical objects. The process uses smart fluid known as magnetorheological polishing fluid. This fluid consists of carbonyl iron (CI) and silicon carbide (SiC) abrasive particles mixed in the base fluid. The magnetorheological cylindrical finishing process consists of an internal finishing tool, which induces magnetic field over its outer surface due to which CI particles experience magnetic force and form chains between the magnetized tool outer surface and inner surface of the cylindrical workpiece. The CI particles push SiC abrasive particles towards the inner surface of the cylindrical workpiece and with the movement of finishing tool inside the cylindrical workpiece, finishing is performed in the process. In the present work, a mathematical model is developed for calculating the change in surface roughness values in the magnetorheological cylindrical finishing process after consideration of forces as acting on SiC particles. To validate the proposed mathematical model, the experimentation is performed by the magnetorheological cylindrical finishing process for finishing the internal surface of cylindrical hardened ferromagnetic steel workpiece. Results of both i.e. mathematical modeling and experimentation are found to be in close agreement with least percentage error of 1.28%. The developed mathematical model is helpful in predicting the process performance, which proves to be useful for industries dealing with internal finishing like injection molding, gas, and liquid pipes, etc.

A Markovian Finishing Process

2008 ◽  
Vol 130 (2) ◽  
Author(s):  
M. A. S. Mohamed
Keyword(s):  
Triangular Form ◽  
Workpiece Surface ◽  
Finishing Process ◽  
Tool Surface ◽  
Markov Matrix ◽  
Abrasive Surface ◽  
Matrix Mapping ◽  
Abrasive Tools ◽  
Finishing Processes ◽  
Abrasive Paper

Addressed is the mechanism of finishing processes for a workpiece surface using hard abrasive tools such as grinding, abrasive paper, and filing. The mechanism is intended to monitor the gradual changes of the workpiece surface state roughness as the tool is applied for several strokes. Based on a number of common features, the present study simulates each rubbing stroke as a Markov process, and each set of several strokes as a Markov chain. In the simulating model, the discrete probabilistic properties of a specific tool abrasive surface can be expressed in terms of a corresponding Markov matrix operator. Thus, the tool action after one rubbing stroke is obtained via a matrix mapping from a given state roughness to a subsequent state roughness of the workpiece surface. Although the suggested model is capable to handle a comprehensive finishing mechanism, the study focuses on the simple case of zero feeding using a hard abrasive tool, in which the Markov matrix shrinks to a special triangular form. Main findings show that major aspects of the tool surface are transferred to the stepwise roughness state of the workpiece immediately after the first stroke. In addition, regardless of the initial roughness state of the workpiece surface, whether with flat or randomly distributed heights, the ultimate state roughness is unique and definitely features the theoretical case of a plain flat surface. However, this theoretical case is infeasible since it can only be reached after infinite number of strokes.

Ultra-High Speed Grinding Using a CBN Wheel for a Mirror-Like Surface Finish

2005 ◽  
Vol 291-292 ◽  
pp. 67-72 ◽  
Author(s):  
M. Ota ◽  
T. Nakayama ◽  
K. Takashima ◽  
H. Watanabe
Keyword(s):  
Surface Finish ◽  
High Speed ◽  
High Efficiency ◽  
Ground Surface ◽  
Machining Process ◽  
Grinding Wheel ◽  
Cbn Wheel ◽  
Ultra High Speed ◽  
High Speed Grinding ◽  
Grinding Conditions

There are strong demands for a machining process capable of reducing the surface roughness of sliding parts, such as auto parts and other components, with high efficiency. In this work, we attempted to grind hardened steel to a mirror-like surface finish with high efficiency using an ultra-high speed grinding process. In the present study, we examined the effects of the work speed and the grinding wheel grain size in an effort to optimize the grinding conditions for accomplishing mirror-like surface grinding with high efficiency. The results showed that increasing the work speed, while keeping grinding efficiency constant, was effective in reducing the work affected layer and that the grinding force of a #200 CBN wheel was lower than that of a #80 CBN wheel. Based on these results, a high-efficiency grinding step with optimized grinding conditions was selected that achieved excellent ground surface quality with a mirror-like finish.

COMPARISON OF EXPERIMENTALLY MEASURED AND SIMULATED WORKPIECE AND GRINDING WHEEL TOPOGRAPHY USING A NEW DRESSING MODEL

2016 ◽  
Vol 40 (1) ◽  
pp. 1-17 ◽  
Author(s):  
Abdalslam Darafon ◽  
Andrew Warkentin ◽  
Robert Bauer
Keyword(s):  
Surface Finish ◽  
Metal Removal ◽  
Ground Surface ◽  
Cutting Edge ◽  
Edge Density ◽  
Grinding Wheel ◽  
Workpiece Surface ◽  
Wheel Topography ◽  
Grinding Wheel Topography ◽  
Grinding Conditions

This paper presents a new empirical model of the dressing process in grinding which is then incorporated into a 3D metal removal computer simulator to numerically predict the ground surface of a workpiece as well as the dressed surface of the grinding wheel. The proposed model superimposes a ductile cutting dressing model with a grain fracture model to numerically generate the resulting grinding wheel topography and workpiece surface. Grinding experiments were carried out using “fine”, “medium” and “coarse” dressing conditions to validate both the predicted wheel topography as well as the workpiece surface finish. For the grinding conditions used in this research, it was observed that the proposed dressing model is able to accurately predict the resulting workpiece surface finish for all dressing conditions tested. Furthermore, similar trends were observed between the predicted and experimentally-measured grinding wheel topographies when plotting the cutting edge density, average cutting edge width and average cutting edge spacing as a function of depth for all dressing conditions tested.

scholarly journals Gauge-Strain-Controlled Air and PWR Fatigue Life Data for 304 Stainless Steel—Some Effects of Surface Finish and Hold Time

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1248
Author(s):  
Marc Vankeerberghen ◽  
Michel De Smet ◽  
Christian Malekian
Keyword(s):  
Fatigue Life ◽  
Surface Finish ◽  
Fatigue Testing ◽  
Hold Time ◽  
Ground Surface ◽  
Fatigue Curve ◽  
304 Stainless Steel ◽  
Polished Surface ◽  
Water Reactor ◽  
Primary Water

We performed environmental fatigue testing in simulated primary water reactor (PWR) primary water and reference fatigue testing in air in the framework of an international, collaborative project (INCEFA-PLUS), where the effects of mean strain and stress, hold time, strain amplitude and surface finish on fatigue life of austenitic stainless steels in light water reactor environments are being studied. Our fatigue lives obtained on machined specimens in air at 300 °C lie close to the NUREG/CR6909 mean air fatigue curve and are in line with INCEFA-PLUS air fatigue lives. Our environmental fatigue lives obtained in simulated PWR primary water at 300 °C lie relatively close to the NUREG/CR6909 mean fatigue curve; derived from the NUREG/CR6909 mean air fatigue curve and the applicable environmental correction factor (Fen). The PWR results show that (1) a polished surface finish has a slightly higher and a ground surface finish a slightly lower fatigue life than the NUREG/CR6909 prediction; (2) the ratio of polished to ground specimen life is ~1.37 at 300 °C and ~1.47 at 230 °C; (3) holds—at zero strain after a positive strain-rate—have a slightly detrimental effect on fatigue life. These results are in line with the INCEFA-PLUS PWR fatigue lives. A novel gauge-strain extensometer was deployed in order to perform a true gauge-strain-controlled fatigue test in simulated PWR primary water.

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