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

Abstract

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.

Response surface methodology based parametric study for AISI H13 die steel using customized designed 3D printed Ti64 multi-nozzle polishing tool

“…The workpiece material was AISI H13 die steel which have good resistance to thermal softening, high hardenability, high strength, high toughness, and is commonly used in the fabrication of dies, molds, cores, die holder blocks, gears, and rolls. 24,25…”

“…The workpiece material was AISI H13 die steel which have good resistance to thermal softening, high hardenability, high strength, high toughness, and is commonly used in the fabrication of dies, molds, cores, die holder blocks, gears, and rolls. 24,25 For reducing the effect of carrier fluid attachment against the outlet wall and to achieve the streamlined flow of slurry jet, the nozzles throat length was taken as 3:0 mm. 26,27 The mixture of 94% pure water (by weight) and 6% Silicon Carbide (SiC) abrasive (by weight) was used.…”

Modeling of surface roughness in a novel magnetorheological gear profile finishing process

“…The cross-sectional area created by the indented AAP leads to material removal from the gear work part surface. The cross-sectional area of the groove (A cs ) is calculated by using equation (33). 32…”

“…31 Alam and Jha 32 developed a theoretical mathematical model for shear and normal forces produced during the finishing operation in the BEMRF process. Singh and Singh 33 developed a theoretical roughness mathematical model for analyzing the finishing mechanism for the external cylindrical surfaces.…”

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.…”