Predicting the Material Removal Rate (MRR) in surface Magnetorheological Finishing (MRF) based on the synergistic effect of pressure and shear stress

Liu, Jia‐Bao; Li, Xiaoyuan; Zhang, Yunfei; Tian, Dong; Ye, Minheng; Wang, Chao

doi:10.1016/j.apsusc.2019.144492

Cited by 57 publications

(17 citation statements)

References 22 publications

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“…Converging gap between the work piece and carrier surface created a shear stress, which is mainly responsible for material removal. The zone of contact is restricted to a spot, which conforms perfectly to the local topography of the part [26].…”

Section: Magnetorheological Finishing (Mrf)mentioning

confidence: 70%

Advances in Nano-finishing of Optical Glasses and Glass Ceramics

Suresh¹,

Rasheed²,

Gupta³

2020

Handbook of Advanced Ceramics and Composites

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Optical glass and glass ceramic components with angstrom-level surface roughness and nanometer-level dimensional accuracy are in potential demand for sophisticated optical fabrication. In recent years, aspherical and free-form surfaces are gaining prominence for high-performance applications. Moreover, the new optical materials and fabrication process which exhibit superior mechanical properties are being developed to meet the stringent requirements and harsh environment. Fabrication of complex-shaped high optical finish components becomes a significant challenge as conventional finishing techniques are unable to machine aspherical or free-form surfaces precisely. This situation demands few highly advanced and precise finishing processes which ensure stress-free surfaces. Mostly, the optical components are fabricated by shaping or pre-finishing methods followed by final finishing processes. Final finishing processes include more deterministic and flexible polishing techniques that can achieve desired surface finish, figure accuracy and surface integrity to make it suitable for shorter wavelength applications. In this chapter, basic principle, mechanism of various material removal processes, and precision polishing techniques such as magnetorheological fluid-based finishing were discussed and are compared with the convention polishing techniques.

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Section: Magnetorheological Finishing (Mrf)mentioning

confidence: 70%

Advances in Nano-finishing of Optical Glasses and Glass Ceramics

Suresh¹,

Rasheed²,

Gupta³

2020

Handbook of Advanced Ceramics and Composites

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“…The relative velocity, normal force, and shear force contributed mostly to the rate of material removal during the surface finishing. 16 The present developed roughness model can be useful to predict the reduction in roughness value for the precise MR finishing of the different external cylindrical surfaces with the rotary rectangular tool core tip surface. The theoretical model of the present process is useful for fine finishing of the various industrial application where precise finishing is an important factor.…”

Section: Introductionmentioning

confidence: 99%

Theoretical investigations into magnetorheological finishing of external cylindrical surfaces for improved performance

Singh

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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Fine finishing entails increased percentage contact area, less friction, and less wear. The magnetorheological finishing is a precision process to obtain the fine finishing on the workpiece surface for improved functional applications. So, the rotary rectangular core-based magnetorheological finishing process is utilized for the precise finishing of the cylindrical external surfaces. The rotary-rectangular shaped tool core tip surface provides the uniformly magnetic flux concentration that further benefit to offer the uniform fine finishing on the cylindrical work-part's external surface. In this work, a theoretical model is developed to predict the reduction in the surface asperities during the magnetorheological finishing of the external cylindrical surfaces. The rotational speed of the rectangular tool core on the rotating cylindrical work-part enhances the relative speed of active abrasives, which decreases the pitch, helix angle, and increases the helical path length. These results enhance the uniform precise finishing on the cylindrical work-parts and also enhances the process performance. For validation of the theoretical roughness model, the experiments have been performed on the cylindrical external surface of the H13 die steel workpiece. The percentage error between the experimentally obtained Ra value and theoretical Ra value is found to be −4.76% to 3.06%, which shows the good agreement between the theoretical model and experimental results. It also shows the practicality and accuracy of the present process while finishing the H13 die steel and it is useful for many industrial applications.

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“…Depending on the construction details of the device, the variable parameters during the MR surface polishing process affecting the material removal rates can generally be summarised as translation oscillation, work gap, period ratio, eccentricity, wheel speed, intensity of the magnetic field generated, and composition of MR slurry [ 15 ].…”

Section: Introductionmentioning

confidence: 99%

Iron-Sepiolite High-Performance Magnetorheological Polishing Fluid with Reduced Sedimentation

Milde

Moučka

Sedlačík

et al. 2022

IJMS

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A sedimentation-stable magnetorheological (MR) polishing slurry on the basis of ferrofluid, iron particles, Al2O3, and clay nanofiller in the form of sepiolite intended for MR polishing has been designed, prepared, and its polishing efficiency verified. Added clay substantially improved sedimentation stability of the slurry, decreasing its sedimentation rate to a quarter of its original value (1.8 to 0.45 mg s−1) while otherwise maintaining its good abrasive properties. The magnetisation curve measurement proved that designed slurry is soft magnetic material with no hysteresis, and its further suitability for MR polishing was confirmed by its magnetorheology namely in the quadratically increased yield stress due to the effect of applied magnetic field (0 to 600 kA m−1). The efficiency of the MR polishing process was tested on the flat samples of injection-moulded polyamide and verified by surface roughness/3D texture measurement. The resulting new composition of the MR polishing slurry exhibits a long-term stable system with a wide application window in the MR polishing process.

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Predicting the Material Removal Rate (MRR) in surface Magnetorheological Finishing (MRF) based on the synergistic effect of pressure and shear stress

Cited by 57 publications

References 22 publications

Advances in Nano-finishing of Optical Glasses and Glass Ceramics

Advances in Nano-finishing of Optical Glasses and Glass Ceramics

Theoretical investigations into magnetorheological finishing of external cylindrical surfaces for improved performance

Iron-Sepiolite High-Performance Magnetorheological Polishing Fluid with Reduced Sedimentation

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