Development of Al2O3-SiO2 based magnetic abrasive by sintering method and its performance on Ti-6Al-4V during magnetic abrasive finishing

Ahmad, Shadab; Singari, Ranganath M.; Mishra, R. S.

doi:10.1080/00202967.2021.1865644

Cited by 28 publications

(9 citation statements)

References 28 publications

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“…AFM medium can be chemically characterized, and its elements can be analysed using energy-dispersive X-ray spectroscopy (EDS) (Ahmad et al , 2021a). EDS analysis indicates present elements in the developed AFM media.…”

Section: Methodsmentioning

confidence: 99%

A novel eco-friendly abrasive media based abrasive flow machining of 3D printed PLA parts using IGWO and ANN

Hashmi

Mali

Meena

et al. 2023

RPJ

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Purpose Three-dimensional (3D) printed parts usually have poor surface quality due to layer manufacturing’s “stair casing/stair-stepping”. So post-processing is typically needed to enhance its capabilities to be used in closed tolerance applications. This study aims to examine abrasive flow finishing for 3D printed polylactic acid (PLA) parts. Design/methodology/approach A new eco-friendly abrasive flow machining media (EFAFM) was developed, using paper pulp as a base material, waste vegetable oil as a liquid synthesizer and natural additives such as glycine to finish 3D printed parts. Characterization of the media was conducted through thermogravimetric analysis and Fourier transform infrared spectroscopy. PLA crescent prism parts were produced via fused deposition modelling (FDM) and finished using AFM, with experiments designed using central composite design (CCD). The impact of process parameters, including media viscosity, extrusion pressure, layer thickness and finishing time, on percentage improvement in surface roughness (%ΔRa) and material removal rate were analysed. Artificial neural network (ANN) and improved grey wolf optimizer (IGWO) were used for data modelling and optimization, respectively. Findings The abrasive media developed was effective for finishing FDM printed parts using AFM, with SEM images and 3D surface profile showing a significant improvement in surface topography. Optimal solutions were obtained using the ANN-IGWO approach. EFAFM was found to be a promising method for improving finishing quality on FDM 3D printed parts. Research limitations/implications The present study is focused on finishing FDM printed crescent prism parts using AFM. Future research may be done on more complex shapes and could explore the impact of different materials, such as thermoplastics and composites for different applications. Also, implication of other techniques, such as chemical vapour smoothing, mechanical polishing may be explored. Practical implications In the biomedical field, the use of 3D printing has revolutionized the way in which medical devices, implants and prosthetics are designed and manufactured. The biodegradable and biocompatible properties of PLA make it an ideal material for use in biomedical applications, such as the fabrication of surgical guides, dental models and tissue engineering scaffolds. The ability to finish PLA 3D printed parts using AFM can improve their biocompatibility, making them more suitable for use in the human body. The improved surface quality of 3D printed parts can also facilitate their sterilization, which is critical in the biomedical field. Social implications The use of eco-friendly abrasive flow finishing for 3D printed parts can have a positive impact on the environment by reducing waste and promoting sustainable manufacturing practices. Additionally, it can improve the quality and functionality of 3D printed products, leading to better performance and longer lifespans. This can have broader economic and societal benefits. Originality/value This AFM media constituents are paper pulp, waste vegetable oil, silicon carbide as abrasive and the mixture of “Aloe Barbadensis Mill” – “Cyamopsis Tetragonoloba” powder and glycine. This media was then used to finish 3D printed PLA crescent prism parts. The study also used an IGWO to optimize experimental data that had been modelled using an ANN.

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Section: Methodsmentioning

confidence: 99%

A novel eco-friendly abrasive media based abrasive flow machining of 3D printed PLA parts using IGWO and ANN

Hashmi

Mali

Meena

et al. 2023

RPJ

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“…The proportion of ferromagnetic and abrasive particles creates suitable pressure and force by FMAB on the workpiece. Ratio of ferromagnetic and abrasive particles used for preparation of MAPs is usually in the range of 60:40 to 80:20 [72]. In MAF, MAPs are used in two forms: (i) unbonded MAPs and (ii) bonded MAPs as shown in figures 3(a) and (b) respectively.…”

Section: Magnetic Abrasive Particlesmentioning

confidence: 99%

“…On magnetic materials, better surface finish and MRR are achieved compared to non-magnetic materials due to more stiffness of FMAB in the former case. Moreover, physical and mechanical characteristics of the material also influence improvement in surface roughness and MRR, such as hardness, toughness etc Some of the materials on which the MAF process was performed were as follows: silicon wafers [92], aluminum alloys [111], stainless steels [105,112], BK7 Optical glass [94], β-TNTZ alloy [113], Ti-6A-4V alloy [72], ceramics [69], Inconel 718 [114]. However, advanced materials are being developed over time, and further investigation is required to improve the MAF process efficiency (especially in non-magnetic material).…”

Section: Hybridization Of Mafmentioning

confidence: 99%

Recent advancements in magnetic abrasive finishing: a critical review

Kumar,

Komma

2024

Eng. Res. Express

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Many engineering applications require components with a good surface finish. It is difficult to get the surface finish in the micro/nano level range with conventional finishing processes for materials such as super alloys, composites, and ceramics. Magnetic abrasive finishing (MAF) is one of the processes for achieving superior surface finish. However, the processes efficiency is affected by its operational variables. Even a slight change in a processing parameter may lead to dimensional inaccuracies and poor surface quality of the workpiece. In this paper, recent trends in the magnetic abrasive finishing process are presented along with a critical review. The review includes MAF principles, tools, hybridization, modeling, and simulation of the process. Apart from plane MAF, the principle of MAF for cylindrical workpieces, the mechanism of material removal and the effect of different types of abrasives are also discussed. Various machine tools used for MAF of plane and cylindrical workpieces for external and internal surfaces are also discussed. In hybridization, different processes combined with MAF, like ultrasonic-assisted MAF, chemo-assisted MAF, and electrochemical-assisted MAF, etc., are discussed to increase material removal rate and obtain surface finish at the micro/nano level. The paper also covers mathematical and statistical modeling, simulation, and optimization techniques to predict and optimize the set of input process parameters. Lastly, challenges and conclusions of the MAF process are presented.

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“…They also revealed that CIP-B 4 C composite abrasives manufactured using the conventional sintering method transfer larger shear stress into the metal surface due to strong particle's matrix strength, resulting in better MRR and surface value of order 122 nm. According to Ahmad et al 13 research, sintered magnetic abrasives were uniformly and tightly bonded with the CIP particles matrix. The magnetic abrasives produced are in three different sizes: 90, 150 and 300 microns.…”

Section: Introductionmentioning

confidence: 99%

“…12 However, due to the high centripetal force caused by the magnet rotational speed, loosely mixed powder begins to fly away from the work zone during the surface finishing process, reducing the process’s effectiveness. 13 Furthermore, loosely mixed abrasive was embedded over the metal surface, creating surface irregularities. 14 The alternative solution is magnetic abrasive in the form of composite powder, which essentially bonded the ferromagnetic material and ceramic abrasives.…”

Section: Introductionmentioning

confidence: 99%

Effect of sintering routes on CIP/EIP – Al₂O₃ composite magnetic abrasive for chemo-mechanical magneto-rheological finishing of aluminium 6061

Kumar

Singh

2022

Proceedings of the Institution of Mechanical Engineers, Part C:

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In magnetorheological fluid-based finishing processes, the lower gripping of abrasives in between ferromagnetic particle’s chain structure limits its finishing speed, resulting in a lower material removal rate and desired surface standard. In addition, tool ageing has significantly impacted these finishing processes at a higher speed. To improve the efficiency of finishing processes, composite magnetic abrasives are fabricated by using powder metallurgy techniques via both microwave and conventional processing (sintering) routes. Comparison studies were performed on these samples based on ferromagnetic materials (CIPs and EIPs) used and sintering at 950°C under fixed element composition. A newly advanced chemo-mechanical magneto-rheological finishing (CMMRF) process for aluminium alloy surface polishing was also proposed, combining mechanical abrasion and chemical action for the performance evaluation of composite magnetic abrasives. Most notably, the microwave processed composite magnetic abrasive outperformed conventionally processed samples in terms of magnetic and rheological properties. The composite magnetic abrasives significantly increased the rate of material removal from the metal surface while reducing the tool ageing effect. The surface profile and observation show that a nearly defect-free surface was produced at higher speeds using these composite magnetic abrasives compared to simply mixed abrasives based results.

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Development of Al₂O₃-SiO₂ based magnetic abrasive by sintering method and its performance on Ti-6Al-4V during magnetic abrasive finishing

Cited by 28 publications

References 28 publications

A novel eco-friendly abrasive media based abrasive flow machining of 3D printed PLA parts using IGWO and ANN

A novel eco-friendly abrasive media based abrasive flow machining of 3D printed PLA parts using IGWO and ANN

Recent advancements in magnetic abrasive finishing: a critical review

Effect of sintering routes on CIP/EIP – Al₂O₃ composite magnetic abrasive for chemo-mechanical magneto-rheological finishing of aluminium 6061

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Development of Al2O3-SiO2 based magnetic abrasive by sintering method and its performance on Ti-6Al-4V during magnetic abrasive finishing

Cited by 28 publications

References 28 publications

A novel eco-friendly abrasive media based abrasive flow machining of 3D printed PLA parts using IGWO and ANN

A novel eco-friendly abrasive media based abrasive flow machining of 3D printed PLA parts using IGWO and ANN

Recent advancements in magnetic abrasive finishing: a critical review

Effect of sintering routes on CIP/EIP – Al2O3 composite magnetic abrasive for chemo-mechanical magneto-rheological finishing of aluminium 6061

Contact Info

Product

Resources

About

Development of Al₂O₃-SiO₂ based magnetic abrasive by sintering method and its performance on Ti-6Al-4V during magnetic abrasive finishing

Effect of sintering routes on CIP/EIP – Al₂O₃ composite magnetic abrasive for chemo-mechanical magneto-rheological finishing of aluminium 6061