Experimental study on the effect of finishing parameters on surface roughness in magneto-rheological abrasive flow finishing process

Abstract

In this study, a novel precision finishing process for complex internal geometries using smart magneto-rheological polishing fluid is developed. Magneto-rheological abrasive flow finishing process provides better control over rheological properties of abrasive-laden finishing medium that exhibits changes in rheological behavior in the presence of external magnetic field. The finishing fluid used in this study contains SiC and iron particles with a combination of specific volume percentage of glycerin and liquid paraffin as abrasive, magnetizable and base medium parts, respectively. The smart characteristics of magneto-rheological fluid are utilized to precisely control finishing forces to control surface quality. A hydro-mechanical device is used to provide experimental setup in order to investigate the effects of different parameters on surface roughness. This device consists of a hydro-mechanical power unit, abrasive fluid containers, permanent NdFe magnets, workpiece fixtures and a base frame. Experiments were conducted on austenitic stainless steel (AISI304), aluminum (7075 alloy) and copper (unalloyed) with different magnetic field strength, abrasive particle size and finishing time cycles. It is observed that by decreasing magnetic field strength, the surface roughness decreases in all three materials. Besides, with increase in abrasive particle mesh number, surface roughness tends to be higher. However, there is a slight difference observed through different finishing cycle times. The specific applications of this process are finishing fluid guidelines in precise instruments like capillary tubes in drug delivery setups.

The Potential of Additive Manufacturing in the Smart Factory Industrial 4.0: A Review

“…In this process, the input material is fed into the system and a fully computer-controlled system and based on the feedback, it will go to the finished parts or it will go back to different stages of the manufacturing process. After the point that the part has met all the required criteria, it will pass the manufacturing stage and gets prepared for other steps prior to being delivered to the customers [85][86][87][88]. Figure 6 represents a future example of how hybrid manufacturing can be conducted in micro/nano-scale in order to have a final product in one machine or one workstation regardless of the steps which take place in order to complete the parts [82].…”

“…There are other applications of AM which do not fall into the above-mentioned categories. Due to the flexibility and multifunctionality, e.g., load-bearing, while being lightweight, of AM lattice structures [113], they have been thoroughly analyzed for energy absorption applications [86]. AM has also been introduced to other industries such as food [114] and clothing [18], because of its flexibility and capability of manufacturing custom products on demand.…”

Investigation into Hand Scraping: A Microanalysis

“…Being a surface finishing process, hand scraping can be compared to other such processes that are based on cutting. While grinding [5,6] and honing are processes with grain kinematics defined by the tool and the machine motion [7], lapping and abrasive flow machining [8] are operating with free grains. All of the above mentioned processes can be categorized as chip removal with geometrically undefined cutting edges and are designed to generate surfaces with minimal roughness and waviness and-in the case of grinding and lapping-good evenness.…”

Enhancement of metallic machine parts mechanical properties by the use of vibratory processing for oxide coated films formation and MoS2 solid lubricant coating deposit

“…These not only reduce the lifespan of industrial components but also increase the maintenance cost and expenditure for replacement of their parts. Since corrosion and wear both occur at the surface of the substrate, they can be reduced or eliminated by surface treatment (Dehghan Ghadikolaei & Vahdati 2015;Shetty, Emigh & Krogstada 2019). In this respect, the metallic surface coating gives a practical solution (Wang, Tzeng, Chen, & Chang, 2012) since machine parts and structures are designed for specific applications (Babichev, Essola, et al, 2011;Fotovvati, Namdari, & Dehghanghadikolaei, 2019).…”