scholarly journals Development of Ultrasonic Vibration-Assisted Magnetic Compound Fluid (MCF) Polishing Technology

2022 ◽  
Vol 16 (1) ◽  
pp. 71-77
Author(s):  
Mitsuyoshi Nomura ◽  
Kenji Ozasa ◽  
Tatsuya Fujii ◽  
Tsunehisa Suzuki ◽  
Yongbo Wu ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Ultrasonic Vibrations ◽  
Elliptical Vibration ◽  
Surface Polishing ◽  
Acrylic Plate ◽  
Experimental Apparatus

This study investigates the development of an ultrasonic vibration-assisted magnetic compound fluid (MCF) polishing technology for final polishing. The fabrication of an experimental apparatus entails an ultrasonic polishing unit, and the experimental investigation of its performance in surface polishing is described. In addition, ultrasonic vibration-assisted MCF polishing under different applied methods of ultrasonic vibration is studied. The experimental results indicate that applying ultrasonic vibration to the workpiece improves the surface roughness and material removal rate when the ultrasonic vibrations are changed. In addition, across the range of polishing conditions employed in this study, the precision surface roughness and high material removal rate can be easily obtained on the acrylic plate by applying an elliptical vibration to the ultrasonic vibration.

A Quasi-Static Mechanics Analysis of Three-Dimensional Nanoscale Surface Polishing

2010 ◽  
Vol 132 (3) ◽  
Author(s):  
H. Xu ◽  
K. Komvopoulos
Keyword(s):  
Surface Roughness ◽  
Steady State ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Three Dimensional ◽  
Polished Surface ◽  
Elastic Plastic ◽  
Surface Polishing ◽  
Mechanics Analysis

A quasi-static mechanics analysis of nanoscale surface polishing that provides insight into the surface topography evolution and the removal of material at the asperity level is presented. The analysis is based on a three-dimensional stochastic model that accounts for multiscale (fractal) surface roughness and elastic, elastic-plastic, and fully plastic asperity deformation by hard abrasive nanoparticles embedded in the soft surface layer of a rigid polishing plate. Numerical results of the steady-state roughness of the polished surface, material removal rate, and wear coefficient are presented in terms of the apparent contact pressure, polishing speed, original topography and mechanical properties of the polished surface, average size and density of nanoparticles, and surface roughness of the polishing plate. Simulation trends are associated with elastic-plastic and fully plastic asperity contacts, responsible for irreversible topography changes (roughening effect) and material removal (smoothening effect), respectively. Analytical trends and predictions of the steady-state roughness of the polished surface and material removal rate are shown to be in good agreement with experimental results of nanoscale surface polishing (lapping) of magnetic recording ceramic heads.

Investigation into Chemo-Mechanical Fixed Abrasive Polishing of Fused Silica with the Assistance of Ultrasonic Vibration

2012 ◽  
Vol 523-524 ◽  
pp. 155-160 ◽  
Author(s):  
Ya Guo Li ◽  
Yong Bo Wu ◽  
Li Bo Zhou ◽  
Hui Ru Guo ◽  
Jian Guo Cao ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Material Removal ◽  
Optical Glass ◽  
Removal Rate ◽  
Fused Silica ◽  
Processing Efficiency ◽  
Machined Surface ◽  
Fixed Abrasive

Ultrasonic vibration assisted processing is well known for the improvement in machined surface quality and processing efficiency due to the reduced forces and tribology-generated heating when grinding hard-brittle materials. We transplanted this philosophy to chemo-mechanical fixed abrasive polishing of optical glass, namely fused silica, in an attempt to improve surface roughness and/or material removal rate. Experiments were conducted to elucidate the fundamental characteristics of chemo-mechanical fixed abrasive polishing of fused silica in the presence and absence of ultrasonic vibration on a setup with an in-house built gadget. The experimental results show that ultrasonic vibration assisted chemo-mechanical fixed abrasive polishing can yield increased material removal rate while maintaining the surface roughness of manufactured optics compared to conventional fixed abrasive polishing without ultrasonic vibration. The mechanism of material removal in fixed abrasive polishing was also delved. We found that the glass material is removed through the synergic effects of chemical and mechanical actions between abrasives and glass and the resultant grinding swarf contains ample Si element as well as Ce element, standing in stark contrast to the polisher that contains abundant Ce element and minor Si element.

Enhancement of machining and surface quality of quaternary alloyed NiTiCuZr shape memory alloy through ultrasonic vibration coupled WEDM

2021 ◽  
pp. 146442072110582
Author(s):  
C Balasubramaniyan ◽  
K Rajkumar ◽  
S Santosh
Keyword(s):  
Surface Roughness ◽  
Shape Memory ◽  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Ultrasonic Frequency ◽  
Machining Parameters ◽  
Pulse On Time ◽  
Pulse Off Time

NiTiCuZr shape memory alloys (SMA) outperform ternary and binary SMA alloys in terms of functional fatigue and higher temperature performance due to their high cyclic stability and transformation temperatures. Owing to the impairment of the shape memory effect during processing, it is difficult to select a manufacturing process for obtaining design functionality with the required dimensions and surface roughness. In this work, a high-temperature NiTiCuZr SMA was machined using an ultrasonic vibration assisted wire electric discharge machine (USV-WEDM). The machining was conducted using various parameters with a constant ultrasonic vibration of 20 kHz provided on a wire-electrode to evaluate surface roughness (Ra) and material removal rate (MRR). Scanning Electron Microscope (SEM) and Energy Dispersive X-Ray analysis (EDX) were utilized to examine the surface integrity and chemical composition of the machined surfaces. MRR increased by 62% with a steady increase in pulse-on time ( Ton) and applied current ( I), whereas increasing levels of parameters such as pulse-off time ( Toff) and servo voltage (SV) reduced surface roughness ( Ra) by 69%. The results reveal that tool vibration at ultrasonic frequency reduces the surface roughness and improves the material removal rate of the machined NiTiCuZr SMA as compared to that of non-ultrasonic assisted machining conditions. SEM-EDX investigation reveals that the formation of re-solidification and oxide layers during NiTiCuZr machining at high machining parameters results in increased hardness and surface roughness. USV-WEDM is a suitable process for machining SMA alloy without adversely impacting SMA properties.

Effects of Combined Ultrasonic Vibration during the Sinking EDM Process for Cemented Carbide

2009 ◽  
Vol 76-78 ◽  
pp. 657-663 ◽  
Author(s):  
Chaiya Praneetpongrung ◽  
Yasushi Fukuzawa ◽  
Shigeru Nagasawa
Keyword(s):  
Surface Roughness ◽  
Ultrasonic Vibration ◽  
Material Removal Rate ◽  
Electrical Discharge ◽  
Material Removal ◽  
Removal Rate ◽  
Cemented Carbide ◽  
Electrode Wear ◽  
Machining Properties ◽  
Edm Process

In recent years, to improve the electrical discharge machining properties, several trials have been applied with the ultrasonic vibration system which was combined on the sinking electrical discharge machine. In this paper, the effects of the ultrasonic vibration were investigated with the designed sinking EDM machine. Some experimental parameters of tool electrode polarity, rotational workpiece speed and directions were examined during the sinking EDM process on the cemented carbide material of G5. Material removal rate, electrode wear ratio and surface roughness were estimated as the machining properties under finishing machining conditions. The experiments were carried out on ultrasonic longitudinal frequency 59 kHz and electrode spindle till 1,000 rpm. Two rotational apparatuses were used simultaneously on the opposite rotational direction during discharge machining. The discharge conditions were estimated with the waveforms analysis. As the results, the EDM device system which was combined ultrasonic vibration, improved the material removal rate and surface roughness of the EDMed workpiece.

Effects of Process Parameters on Surface Roughness and MRR in the hard turning of EN 36 steel

2018 ◽  
pp. 102-110
Author(s):  
Amritpal Singh ◽  
Rakesh Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Control Parameter ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting

In the present study, Experimental investigation of the effects of various cutting parameters on the response parameters in the hard turning of EN36 steel under the dry cutting condition is done. The input control parameters selected for the present work was the cutting speed, feed and depth of cut. The objective of the present work is to minimize the surface roughness to obtain better surface finish and maximization of material removal rate for better productivity. The design of experiments was done with the help of Taguchi L9 orthogonal array. Analysis of variance (ANOVA) was used to find out the significance of the input parameters on the response parameters. Percentage contribution for each control parameter was calculated using ANOVA with 95 % confidence value. From results, it was observed that feed is the most significant factor for surface roughness and the depth of cut is the most significant control parameter for Material removal rate.

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

Enhancement of EDM Performance by Using Copper-Silver Composite Electrode

2020 ◽  
Vol 38 (9A) ◽  
pp. 1352-1358
Author(s):  
Saad K. Shather ◽  
Abbas A. Ibrahim ◽  
Zainab H. Mohsein ◽  
Omar H. Hassoon
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Composite Electrode ◽  
Removal Rate ◽  
Pure Copper ◽  
High Speed Steel ◽  
Pulse On Time ◽  
Pulse Off Time

Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.

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