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

Abstract

The present study focused on surface texture characteristics of magnetic material, Mild steel (MS) as well as nonmagnetic material, Aluminum 2024 (Al 2024) alloy with the application of a laboratory-developed magnetic abrasive finishing (MAF) process. MAF is one of the unconventional finishing processes to attain a satisfactory finishing level up to nanoscale. In MAF, the surface finish is controlled by a flexible magnetic abrasive brush (FMAB) which has a combination of abrasives (Al2O3, SiC, etc.) and magnetic particles (iron powder). The experiments were planned using (L27) full factorial design, different levels of weight percentage of abrasives (20–30%), speed of the electromagnet (180–2100rpm), and electromagnet supply voltage (30–50 V) were varied to enhance the surface responses. The responses considered were % improvements of change in the surface finish (%ΔRa), change in average peak to valley height (%ΔRz), change in total profile height (%ΔRt), and change in mean square root surface finish (%ΔRq). Analysis of variances (ANOVA) was evaluated and discussed. It is observed that the speed of the electromagnet and voltage are the most influencing variable parameters that most impacted on the responses. Surface roughness was measured before and after the MAF processing of MS and Al 2024 using a Suftronic S-100 surface roughness tester. The obtained surface morphology was examined by Scanning Electron Microscopy (SEM). It was observed that MS has %ΔRa = 83, %ΔRz = 65, %ΔRt = 65.5 and %ΔRq = 72.6 while Al 2024 has %ΔRa = 65, %ΔRz =50, %ΔRt = 51 and %ΔRq = 55 with noticeable surface texture improvement compared to the initial surface roughness obtained using surface grinding process.

Peculiarities of Abrasive Finishing of Surfaces of Parts Made of Aluminium Alloy of АМts Grade in Magnetic Field

“…Studies of abrasive finishing of aluminium and its alloys in a magnetic field have received considerable attention in literature (23,24). For example, in the work of Khomich (23) the influence of technological tool on the number of inclusions, micro-sharpening and removal of oxide film from the flanks of sheets from aluminium alloy of Al-Mg system (grades 1560 (AMg-6)) was studied.…”

“…It is noted that rational selection of mode parameters and type of technological tool allows to perform defect-free abrasive finishing of sheet edges in a magnetic field. The criteria of surface roughness and its morphology after abrasive finishing in a magnetic field of surfaces of parts made of aluminium alloy of Al-Cu-Mg system (grades 2024 (D16)) has been analyzed in the work of Anjaneuli and Venkatesh (24). It was revealed that the following factors have the main influence on the quality of parts surfaces: stress, allowing to change the stiffness of the technological tool; feed rate, providing the process of micro-cutting.…”

Experimental investigations into the nano-finishing of Al2024 tubes using the rotational-magnetorheological abrasive flow finishing (R-MRAFF) process

“…32 To overcome these challenges, Venkatesh et al 33 studied the surface integrity of Al2024 using the ultrasonic-assisted abrasive flow machining (UAAFM) process, and the authors found that the percentage change in surface roughness of Al2024 was improved by 85.12%. In another attempt, Anjaneyulu and Venkatesh 34 proposed magnetic abrasive finishing (MAF) process to improve the surface texture of Al2024, and they reported that the surface texture of Al2024 was improved by 65%.…”

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

“…1 Several established finishing processes use MR-fluid as a polishing medium, including magneto-rheological finishing (MRF), magneto-rheological abrasive flow finishing (MRAFF), rotational magneto-rheological finishing (R-MRAFF) and ball end magnetorheological finishing (BEMRF). [2][3][4] Ferromagnetic particles, abrasive, carrier mediums and essential additives are primary constituents of these fluids. 5 The action of ferromagnetic and abrasive particles as they form a soft magnetic abrasive brush will have a significant impact on the performance of the MR-fluid.…”