A trend toward abrasive nano finishing of plane surfaces with magnetic field energy

Abstract

In new developed parts, roughness has become an effective parameter and influences the performance of the entire system. Manufacturing of parts with fine surface finish have been a target for many advanced industries. Sometimes, it is difficult to reach highly polished surface quality by conventional methods. One of the newly introduced methods for obtaining fine finished surfaces is nano‐scale finishing with abrasive particles in magnetic fields. It is a relatively new finishing process that can be used to produce efficiently shiny surface quality for certain parts [1]. In this process, the cutting movement is provided by the magnetic field energy of permanent or electric poles. Magnetic abrasive particles (MAPs) are used to remove chips, and polish the work‐piece surface [2, 3]. The work‐piece is in the shape of a flat plane. An apparatus has been designed and made for machining the upper face of the plane. Nd‐Fe‐B magnets are used to establish the magnetic field. An NC machine is applied to create the rotational movement of MAPs in the horizontal plane and maintain the vertical position accurately. Various experiments have been designed to specify the machining characteristics of the MAF process. In these experiments different effective conditions are determined. Permanent magnets with 1.2 T magnetic flux density are used as magnetic poles. Homogeneous mechanical mixture of abrasive powder (Silicon Carbide) and ferromagnetic iron particles are used as the MAPs. The experimental setup was designed for finishing the aluminium alloy AA–6061. Test results indicated that the finishing parameters affect the material removal rate (MRR) and surface roughness.

Magnetorheological Fluid Finishing of Soft Materials: A Critical Review

“…Results showed that even though the MRF material removal process is dominated by mechanics, chemical durability of glass and hence the pH of the MR fluid play a role in the process. Vahdati&Shokuhfar [11] experimentally indicated the effects of various finishing parameters viz. rotational speed of magnet holder (pole N), operation time, abrasive type, working gap between magnet holder and work-piece, and lubricant type on material removal rate (MRR) and surface roughness during finishing of aluminium alloy AA-6061.…”

Experimental and theoretical investigation into surface roughness and residual stress using ball end magnetorheological finishing

“…Considering low resistivity to scratching of aluminium, it becomes difficult to achieve nano level surface finish without damaging the surface integrity using conventional finishing processes. Vahdati (2008) found that various finishing constraints such as finishing tool rotation, duration of finishing, type of abrasives, distance between magnetic tool & workpiece, lubricant used and finishing forces acting on the workipece can influence the removal rate of material and finish of the surface. Khan (2019) observed that the fluid composition especially the abrasive mesh size is an important parameter for finishing soft material like copper.…”

Micro machining of high-hardness materials using magnetic abrasive grains

“…Kim 18 investigated how the machining conditions affect on surface roughness by applying magnetic abrasive using WC-Co abrasive particles to the inner surface of STS 304 pipe and clarified that the surface roughness gets improved as the magnetic flux increases. Vahdati 19 used a NC machine to perform precise machining of the surface of aluminum alloy flat plate, obtained a surface roughness of Ra 0.6 ㎛ using a Nd-Fe-B permanent magnet and a magnetic abrasive tool, and reported that the optimum distance between a rotating pole and the workpiece is 5 mm. Park 20 fabricated a magnetic abrasive device that incorporated a magnetic pole vibration method to perform inner abrasion of pipe.…”