Development of Mathematical Model and Characterization of Internal Surface Obtained by Elasto-Abrasives Magneto-Spiral Finishing (EAMSF)

Abstract

The implantation of stents and instruments with capillary action demands super-finished internal surfaces of the manufactured product. Elasto-abrasives magneto-spiral finishing (EAMSF) enhances the productivity of finishing by incorporating the abrasive flow in spiral motion due to the presence of the magnetic field. Here, novel impregnated elasto-magnetic abrasive particles (IMPs) are used in a magnetic field-assisted environment to polish the inner walls of the workpiece. In EAMSF, magnetic force provides excess finishing pressure to the abrasives whereas the elasticity of the high impact polystyrene (HIPS) absorbs the excess force of the IMPs on the finishing surface. An indigenous mathematical relation taking into account the physics of process indicating material removal shows a close resemblance to the experimental results with an error percentage of 1.03 has been developed. The results of experimentation revealed that with 50% concentration of abrasives and a magnetic field density of 18mT yields, a superior surface finish with a Ra value equal to 0.053 μm and maximum material removal of 6.9 mg; while in the absence of a magnetic field, superior surface finish with a Ra = 0.266μm and maximum material removal of 5.4 mg is achieved. In the presence of magnetic field density, significant enhancement of material removal, surface finish, and burr removal is observed. Finishing of the surface at 50% abrasive concentration with a magnetic field represents regular finishing and the trench marks present in the original surface are removed after finishing.