Evaluation of Parameters Affecting Magnetic Abrasive Finishing on Concave Freeform Surface of Al Alloy via RSM Method

Abstract

The attempts of researchers in industries to obtain accurate and high quality surfaces led to the invention of new methods of finishing. Magnetic abrasive finishing (MAF) is a relatively new type of finishing in which the magnetic field is used to control the abrasive tools. Applications such as the surface of molds are ones of the parts which require very high surface smoothness. Usually this type of parts has freeform surface. In this study, the effect of magnetic abrasive process parameters on freeform surfaces of parts made of aluminum is examined. This method is obtained through combination of magnetic abrasive process and Control Numerical Computer (CNC). The use of simple hemisphere for installation on the flat area of the magnets as well as magnets’ spark in curve form is a measure done during testing the experiments. The design of experiments is based on response surface methodology. The gap, the rotational speed of the spindle, and the feed rate are found influential and regression equations governing the process are also determined. The impact of intensity of the magnetic field is obtained using the finite element software of Maxwell. Results show that in concave areas of the surface, generally speaking, the surface roughness decreases to 0.2 μm from its initial 1.3 μm roughness. However, in some points the lowest surface roughness of 0.08 μm was measured.

Surface texture improvement of magnetic and non magnetic materials using magnetic abrasive finishing process

“…A comparison of the effect of permanent magnet and electromagnet on R a improvement of the aluminium using MAF process was carried out by Kim et al 11 It is noticed that the effect of R a improvement is better with electromagnet compared with a permanent magnet. Similar kind of studies has been carried out on the MAF process by Mehrdad et al and Yi Hsun et al 12,13 Vipin et al 14 studied the effect of different abrasives in the MAF process and found that abrasives with bonded type gave better R a compared to unbounded abrasives. Moreover, the preparation of bonded abrasives is difficult and time taking process because it must be sintered in the inert gas atmosphere at high pressure and temperature.…”

Review of Superfinishing by the Magnetic Abrasive Finishing Process

“…Vahdati and Rasouli et al [28] evaluated how process parameters affected MAF on a concave free-form surface of an Al alloy workpiece via the RSM method. To perform the MAF process, unbonded magnetic abrasive powder was used.…”

Study on Magnetic Abrasive Finishing Combined with Electrolytic Process–Precision Surface Finishing for SUS 304 Stainless Steel Using Pulse Voltage

“…In addition, the magnetic field has penetrating properties, and a magnetic brush can be formed in the cavity of a workpiece. Therefore, the MAF process can be used to finish the inner cavity of workpiece [5][6][7]. Due to the advantages of the magnetic finishing tool, the MAF process is widely used in industrial fields that require precision finishing [1][2][3][4][5][6][7][8].…”

“…Therefore, the MAF process can be used to finish the inner cavity of workpiece [5][6][7]. Due to the advantages of the magnetic finishing tool, the MAF process is widely used in industrial fields that require precision finishing [1][2][3][4][5][6][7][8]. However, the flexible magnetic finishing tool also has disadvantages-insufficient finishing efficiency is one of the factors that affect its large-scale promotion.…”