Analysis of Surface Finish Improvement during Ultrasonic Assisted Magnetic Abrasive Finishing on Chemically treated Tungsten Substrate

Sihag, Nitesh; Kala, Prateek; Pandey, Pulak M.

doi:10.1016/j.promfg.2017.07.040

Cited by 29 publications

(10 citation statements)

References 22 publications

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“…On other hand, initially PIESF starts decreasing (up to 120 RPM) and afterward, it starts increasing by enhancing the surface rotational speed. The abrasive particles strike on the workpiece surface very rapidly by enhancing the rotational speed, and the surface-finishing rate is increased, which results in more peaks being reduced from the surface [ 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 , 19 , 20 , 21 , 22 , 23 , 24 , 27 ]. Figure 5 b shows that PIESF is highest at an abrasive size of 40 µm and a chemical concentration of 700 gm/lt.…”

Section: Resultsmentioning

confidence: 99%

“…However, instead of having many advantages, MAF is less effective at finishing hard materials such as Inconel alloy, tungsten and titanium, due to their superior materialistic characteristics [ 18 , 19 ]. Therefore, chemically assisted magnetic abrasive finishing (CMAF) has recently been developed for machining hard superalloys [ 20 , 21 ]. The CMAF process is the integration of chemical etching and MAF.…”

Section: Introductionmentioning

confidence: 99%

“…Sihag et al [ 20 ] implemented a chemo-assisted MAF process to finish a tungsten plane surface, and the surface finish was improved by around 79.52% with optimum conditions. Singh et al [ 27 ] used chemical-assisted MAF on Inconel 718 flat surfaces and recommended higher processing time (90 min) and wt% of abrasives (35%) to enhance the MR. Sihag et al [ 21 ] further developed a new hybrid process by integrated ultrasonic vibration, MAF and chemical machining. Experiments were performed on an H2O2 chemical-treated tungsten flat surface and results reported that pulse-on time in ultrasonic vibrations produces extreme impact (21.99%) for altering the surface roughness.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Multiobjective Optimization of Chemically Assisted Magnetic Abrasive Finishing (MAF) on Inconel 625 Tubes Using Genetic Algorithm: Modeling and Microstructural Analysis

Singh

Kumar

Kansal³

et al. 2022

Micromachines

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The demand for the surface integrity of complex structures is drastically increasing in the field of aerospace, marine and automotive industry. Therefore, Inconel alloy, due to its superior attributes, has a wide scope for the improvement in surface integrity. To achieve the precise surface finish and enhance the process performance, process optimization is necessary. In current paper, chemically assisted MAF process parameters were optimized using the genetic algorithm (GA) approach during finishing of Inconel 625 tubes. Regression models were developed for improvement in internal surface finish (PIISF), improvement in external surface finish (PIESF), and material removal (MR) using Design expert software. Then, the surface microstructure of Inconel 625 tubes was analyzed using scanning electron microscopy (SEM). ANOVA analysis predicts that processing time and abrasive size have the highest percentage contribution in improving the surface finish and material removal. Multioptimization results suggested to set the level of processing time (A) at 75 min, surface rotational speed (B) at 60 RPM, weight % of abrasives (C) at 30%, chemical concentration (D) at 500 gm/lt and abrasive size (E) at 40 microns to obtain optimal parameters for PIISF, PIESF and MR responses.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Multiobjective Optimization of Chemically Assisted Magnetic Abrasive Finishing (MAF) on Inconel 625 Tubes Using Genetic Algorithm: Modeling and Microstructural Analysis

Singh

Kumar

Kansal³

et al. 2022

Micromachines

View full text Add to dashboard Cite

show abstract

“…Experimental results indicate that the proposed MAF setup is able to improve the surface quality of internal grooves by 70%, from 1.12 μm to 0.32 μm, with only 30 mg material loss, which further verifies the capability of MAF in internal surface finishing. Mulik and Pandey [ 19 ] developed the ultrasonic-assisted magnetic abrasive finishing (UMAF) process which combines ultrasonic vibration and MAF to achieve quick surface finishing, and was successfully achieved to polish a hardened steel workpiece to 22 nm in 80 s. Sihag et al [ 20 ] further enhanced the UMAF process into a chemo ultrasonic assisted magnetic abrasive finishing, resulting 86% surface roughness reduction. Research on magnetic abrasive particles (MAPs) was also conducted in the literature [ 21 , 22 ], which summarized the polishing performance of various types of MAPs fabricated by different processes, and concluded that sintered MAPs show the strongest bonding and highest material removal.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation on the Effect of Surface Shape and Orientation in Magnetic Field Assisted Mass Polishing

et al. 2022

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Magnetic field assisted finishing (MFAF) technology has been widely used in industries such as aerospace, biomedical, and the optical field for both external and internal surface finishing due to its high conformability to complex surfaces and nanometric surface finishing. However, most of the MFAF methods only allow polishing piece-by-piece, leading to high post-processing costs and long processing times with the increasing demand for high precision products. Hence, a magnetic field-assisted mass polishing (MAMP) method was recently proposed, and an experimental investigation on the effect of surface posture is presented in this paper. Two groups of experiments were conducted with different workpiece shapes, including the square bar and roller bar, to examine the effect of surface orientation and polishing performance on different regions. A simulation of magnetic field distribution and computational fluid dynamics was also performed to support the results. Experimental results show that areas near the chamber wall experience better polishing performance, and the surface parallel or inclined to polishing direction generally allows better shearing and thus higher polishing efficiency. Both types of workpiece show notable polishing performance where an 80% surface roughness improvement was achieved after 20-min of rough polishing and 20-min of fine polishing reaching approximately 20 nm.

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“…Different traditional and modern techniques are nominated to enhance surface quality of the workpiece according to cost, time, workpiece material, and surface complexities demands. In recent decades, the vibration of a tool or workpiece is known as an efficient assistant technique in conventional [1][2][3][4][5][6][7][8][9][10][11][12][13] and non-conventional [14][15][16][17][18][19][20][21][22][23][24][25][26][27][28][29][30][31] machining processes. Vibratory and ultrasonic machining are two main non-conventional polishing processes, which are based on vibration phenomenon.…”

Section: Introductionmentioning

confidence: 99%

Surface roughness study of polyamide in nano-metric polishing using low-frequency acoustic energy

Beigmoradi

Vahdati

2021

Proceedings of the Institution of Mechanical Engineers, Part B:

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Polymers have gained the attention of manufacturers due to their significant advantages such as low density, high corrosion resistance, and high humidity resistance. Producing high-precision polymeric components is one the most challenging issues especially in fabricating complex or micro-scale systems. Some of the machining techniques such as electro discharge machining (EDM) and electrochemical machining (ECM) cannot be employed for machining the non-conductive parts. Using abrasive particles is one of the best options for machining these types of materials. In this work, the capability of the acoustic energy for machining polyamide (PA) workpieces is studied. To this end, an experimental setup is installed and design of experiment (DoE) algorithm is employed to survey the effect of process parameters on surface roughness. Three parameters at three levels are considered as the effective factors of the process and the sensitivity of the surface roughness on the process factors is investigated. In the next step, a hybrid finite element/boundary element approach was used to discuss the relation of process parameters to the vibrational characteristics of the container, then the mechanism of the process was investigated employing the discrete element method. Finally, the surface topology of the optimal workpiece before and after the process was presented and compared. It was observed that acoustic energy can be considered as a vibration source of the container’s floor to provide kinetic energy for machining PA parts on the nano-metric scale. Moreover, it was found that the initial roughness of the workpiece and the chosen parameters play a crucial role in the machining process. Experimental results show that in this technique by selecting appropriate process factors the surface roughness can be reduced up to 50%.

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Analysis of Surface Finish Improvement during Ultrasonic Assisted Magnetic Abrasive Finishing on Chemically treated Tungsten Substrate

Cited by 29 publications

References 22 publications

Multiobjective Optimization of Chemically Assisted Magnetic Abrasive Finishing (MAF) on Inconel 625 Tubes Using Genetic Algorithm: Modeling and Microstructural Analysis

Multiobjective Optimization of Chemically Assisted Magnetic Abrasive Finishing (MAF) on Inconel 625 Tubes Using Genetic Algorithm: Modeling and Microstructural Analysis

Experimental Investigation on the Effect of Surface Shape and Orientation in Magnetic Field Assisted Mass Polishing

Surface roughness study of polyamide in nano-metric polishing using low-frequency acoustic energy

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