Force Measurement and Analysis for Magnetic Field–Assisted Finishing

2013 ◽  
Vol 135 (4) ◽  
Author(s):  
Vasishta Ganguly ◽  
Tony Schmitz ◽  
Arthur Graziano ◽  
Hitomi Yamaguchi
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Material Removal ◽  
Force Measurement ◽  
Removal Rate ◽  
Iron Particle ◽  
Free Form ◽  
Total Force ◽  
Polishing Force ◽  
Free Form Surfaces

Magnetic field–assisted finishing (MAF) is used to polish free-form surfaces. The material removal mechanism can be described as a flexible “magnetic brush” that consists of ferromagnetic particles and abrasives that arrange themselves in the working gap between the magnet and the workpiece. Relative motion between the brush and the workpiece causes microcutting and improves surface finish. In this study, the contributions of the magnetic and polishing force components to the total force were evaluated. The effect of varying the polishing conditions, such as the working gap and the size of the ferromagnetic iron particles, on polishing forces, surface roughness, and material removal rate was also analyzed. It was observed that the polishing forces varied considerably with working gap. Also, the iron particle size was found to have a strong relation to the rate at which the surface roughness improved. Surface roughness values of 2–3 nm were achieved.

An Analysis of Polishing Forces in Magnetic Field Assisted Finishing

2012 ◽  
Author(s):  
Vasishta Ganguly ◽  
Tony Schmitz ◽  
Arthur A. Graziano ◽  
Hitomi Yamaguchi
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Iron Particle ◽  
Free Form ◽  
Work Piece ◽  
Total Force ◽  
Polishing Force ◽  
Strong Relation ◽  
Force Components ◽  
Free Form Surfaces

Magnetic field assisted finishing (MAF) is used to polish free-form surfaces. The material removal mechanism can be described as a flexible “magnetic brush” that consists of ferromagnetic particles and abrasives that arrange themselves in the working gap between the magnet and the work piece. Relative motion between the brush and the work piece causes micro-cutting and improves surface finish. In this study, the contributions of the magnetic and polishing force components to the total force were evaluated. The effect of varying the polishing conditions, such as the working gap and the size of the ferromagnetic iron particles, on polishing forces and surface roughness was also analyzed. It was observed that the polishing forces varied considerably with working gap. Also, the iron particle size was found to have a strong relation to the rate at which the surface roughness decreased. Surface area roughness of 2–3 nm was achieved.

Study on Uniform Magnrtorheological Finishing Technology with Changeable Removal Rate Model Based on Rheological Effect

2011 ◽  
Vol 305 ◽  
pp. 186-191
Author(s):  
Xin Sheng He ◽  
Chun Fu Gao ◽  
Bin Wang ◽  
Zhi Yong Luo
Keyword(s):  
Magnetic Field ◽  
Field Distribution ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Magnetic Field Distribution ◽  
Free Form ◽  
Rate Model ◽  
Material Removal Model ◽  
Rheological Effect

At present, the finish machining process of workpiece with free-form surface has the disadvantages of complex trajectory planning, low machining efficiency and precision. To solve these problems, a material removal model whose removal rate model can change with the profile of the workpiece is proposed in this paper. The working mechanism of this method is described as follows: the rheological effect of magnrtorheological fluid is used to change the magnetic field distribution in finishing areas; then the finishing pressure distribution is changed, that makes the material removal rate of every point in the contact area be approximately equal so the aim of uniform removal is achieved. The experiments identify the quantitative relationship between magnetic field intensity and finishing pressure. Contrast experiments of finishing and removal effects are performed under the different conditions of magnetic field distribution. The experiments results show that the proposed method is feasible and this method has the potential of obtaining the ultra precision.

A study on magnetic field assisted laser percussion drilling and its effect on surface integrity

2018 ◽  
Vol 1 (94) ◽  
pp. 35-40
Author(s):  
S. Balamurugan ◽  
C. Bala Manikandan ◽  
P. Balamurugan
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Aluminium Alloy ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Laser Drilling ◽  
Machining Process ◽  
Profile Error ◽  
Taper Angle

Purpose: of this paper is to reduce the taper angle and surface roughness of the laser drilled hole on Aluminium alloy with the assistance of magnetic field. At lower laser powers, able to achieve higher material removal rate in drilling with reduced taper angle and roughness. Design/methodology/approach: Aluminium alloy is a highly reflective material, while laser drilling it ejects plumes, which makes the drilling unreliable. The plume generated due to this action causes deteriorating effects over the work piece as such affecting surface textures. Removal of plume is the major consideration in laser machining process, especially in laser assisted drilling. The plume is a form of cluster of ions having charges in it. Due to the magnetic field input, the ions line the path along the lines of force of magnets. Thus, the ion cloud can be cleared at the localized plane, where the subsequent laser drilling going to be happens, leads to reduced plume thereby reduces the taper angle and surface roughness. Findings: The defect of percussion laser drilling that is barrelling effect in the drilled hole was reduced with the assistance of magnetic field setup. For the laser energy of 90 mJ, the magnetic assisted laser drilling shows better improvement in the material removal rate of 64.5%, the profile error (spatter height) was reduced to 45% and the taper angle of the drilled hole also reduced by 16.3%. The results confirmed the fact that, the Lorentz force confined the plume particle to be raised upwards and circulated outwards to the sidewall from the centre of the laser beam. This expansion of laser induced plasma plume, improved the material removal rate of the hole. Research limitations/implications: Laser drilling was carried out by a constant magnetic field and the parameters like material removal rate, taper angle, profile error, surface roughness were studied. In the future work, these parameters were studied with the application of varying magnetic field. Practical implications: As a result of the work, laser drilling was carried out on turbine blades or complex shapes for retention properties, with reduced taper hole and surface roughness, thereby improving the efficiency of the systems. Originality/value: The novelty of the work is providing magnetic flux for the laser drilling process, which improves the process parameters. The incorporation of magnetic field to the laser drill needs a cost less setup, which can ensure reliable improvement in the material removal rate, reduction in taper angle and profile error.

Influence of Magnetic Field Strength on Polishing Effect of the Tiny-Grinding Wheel Cluster Based on the Magnetorheological Effect

2010 ◽  
Vol 443 ◽  
pp. 406-410 ◽  
Author(s):  
Jie Wen Yan ◽  
Qiu Sheng Yan ◽  
Jia Bin Lu ◽  
Wei Qiang Gao
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Field Strength ◽  
Magnetic Field Strength ◽  
Material Removal Rate ◽  
Carbonyl Iron ◽  
Material Removal ◽  
Optical Glass ◽  
Removal Rate ◽  
Grinding Wheel

A new tiny-grinding wheel cluster polishing method based on the Magnetorheological (MR) effect is presented to polish optical glass in this paper and some process experiments were conducted to reveal the influence of magnetic field strength, the content of carbonyl iron in the MR fluid and the speed of polishing disc on the material removal rate and the surface roughness of the glass workpiece. The results indicate that when the external magnetic field is applied, the material removal rate of the workpiece improves rapidly but the surface roughness increases slightly. When the Magnetic field strength is 100 Gs and the content of carbonyl iron is 3.5%, the material removal rate improves by a factor of 16.8% compared with that of the conventional polishing methods with dissociative abrasive particles, while the surface roughness of the workpiece increases unobviously.

Experimental and Mechanism Research on EDM Combined with Magnetic Field

2009 ◽  
Vol 416 ◽  
pp. 337-341 ◽  
Author(s):  
Ming Rang Cao ◽  
Yan Qing Wang ◽  
Sheng Qiang Yang ◽  
Weng Hui Li
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Material Removal Rate ◽  
Discharge Current ◽  
Material Removal ◽  
Discharge Channel ◽  
Removal Rate ◽  
Machining Parameters ◽  
Mechanism Research ◽  
First Time

The two disadvantages of EDM are the low material removal rate (MRR) and poor surface quality. In this investigation, EDM assisted by magnetic field (MFEDM) has been proposed for the first time to overcome above-mentioned disadvantages. Constant magnetic field was applied to the both sides of discharge channel perpendicularly to form a novel process. In experiment, EDM machine tool D703F was used to machine nonferromagnetic materials. The machining parameters discharge current and pulse duration were chosen to determine the effects on material removal rate and surface roughness.Experiment results indicate that the MRR of the combined machining is 1.2~3 times of EDM’s one. Furthermore, the value of surface roughness is also reduced. Therefore, the introduction of magnetic field to EDM has important academic and practical values to the development of EDM.

Effects of Process Parameters on Surface Roughness and MRR in the hard turning of EN 36 steel

2018 ◽  
pp. 102-110
Author(s):  
Amritpal Singh ◽  
Rakesh Kumar
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
Hard Turning ◽  
Control Parameter ◽  
Removal Rate ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting

In the present study, Experimental investigation of the effects of various cutting parameters on the response parameters in the hard turning of EN36 steel under the dry cutting condition is done. The input control parameters selected for the present work was the cutting speed, feed and depth of cut. The objective of the present work is to minimize the surface roughness to obtain better surface finish and maximization of material removal rate for better productivity. The design of experiments was done with the help of Taguchi L9 orthogonal array. Analysis of variance (ANOVA) was used to find out the significance of the input parameters on the response parameters. Percentage contribution for each control parameter was calculated using ANOVA with 95 % confidence value. From results, it was observed that feed is the most significant factor for surface roughness and the depth of cut is the most significant control parameter for Material removal rate.

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

Enhancement of EDM Performance by Using Copper-Silver Composite Electrode

2020 ◽  
Vol 38 (9A) ◽  
pp. 1352-1358
Author(s):  
Saad K. Shather ◽  
Abbas A. Ibrahim ◽  
Zainab H. Mohsein ◽  
Omar H. Hassoon
Keyword(s):  
Surface Roughness ◽  
Material Removal Rate ◽  
Material Removal ◽  
High Speed ◽  
Composite Electrode ◽  
Removal Rate ◽  
Pure Copper ◽  
High Speed Steel ◽  
Pulse On Time ◽  
Pulse Off Time

Discharge Machining is a non-traditional machining technique and usually applied for hard metals and complex shapes that difficult to machining in the traditional cutting process. This process depends on different parameters that can affect the material removal rate and surface roughness. The electrode material is one of the important parameters in Electro –Discharge Machining (EDM). In this paper, the experimental work carried out by using a composite material electrode and the workpiece material from a high-speed steel plate. The cutting conditions: current (10 Amps, 12 Amps, 14 Amps), pulse on time (100 µs, 150 µs, 200 µs), pulse off time 25 µs, casting technique has been carried out to prepare the composite electrodes copper-sliver. The experimental results showed that Copper-Sliver (weight ratio70:30) gives better results than commonly electrode copper, Material Removal Rate (MRR) Copper-Sliver composite electrode reach to 0.225 gm/min higher than the pure Copper electrode. The lower value of the tool wear rate achieved with the composite electrode is 0.0001 gm/min. The surface roughness of the workpiece improved with a composite electrode compared with the pure electrode.

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