Fine surface finish is in high demand in modern time, with the development of industry manufacturing technology, in a wide range of industrial applications. Now a days, in medical instruments and aerospace components, fine surface finish is highly desirable. The inner surfaces of workpieces used in critical applications are finished using magnetic abrasive finishing (MAF) process. The process principle and the finishing characteristics of MAF of cylindrical pipes using sintered magnetic abrasives are described in this research work. The surface roughness measurements and material removal rate (MRR) measurements resulting from finishing experiments are described in this research work. Response surface methodology (RSM) technique is used for optimization of process parameters for the analysis of surface roughness in terms of percent improvement in surface finish (PISF) and MRR. The obtained maximum PISF was 92 %, and minimum surface roughness was 0.04 lm. The surface was microscopically examined using scanning electron microscopy (SEM) to further study the improvement in surface finish.
Magnetically assisted abrasive finishing (MAAF) presents an attractive concept of surface and edge finishing by fine magnetic abrasive particles (MAPs). This study aims to contribute an experimental evaluation of the effect of process parameters viz. magnetic field density (MFD), circumferential speed of workpiece, and abrasive grit size on the surface finishing properties in MAAF when experiments were performed for finishing pipes of ASTM B16 brass material with the sintered MAPs. The developed model is based on the obtained experimental data accompanied by “Box- Behnken design (BBD) of response surface methodology (RSM)” analysis. Apart from deciding significant parameters, this analysis also presents the modeling of finishing properties and optimizes the desired performance parameters. Analysis of variance (ANOVA) includes data of standard deviation, coefficient of determination (R2), adjusted, and predicted (R2). MFD and speed show a significant effect on both the responses viz. “surface roughness improvement rate (SRIR) and material removal rate (MRR)”. Analysis has shown that abrasive grit size is the most dominant parameter towards SRIR followed by MFD. The maximum SRIR of 88.12% (minimum Ra 50 nm) and 4.28 mg/min is achieved through multi-objective optimization with 0.8 T MFD, 500 rpm speed, and 300 µm grit size. The mathematical models of SRIR and MRR were also developed using RSM, focusing on varying MFD, speed, and grit size which can be used to predict the desired surface finishing properties. The model generated for SRIR, and MRR has an error of 0.204 % and 2.506 % respectively. Further SEM images were taken to understand the surface appearance of the finished surface.
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