Analysis of Forces During Spot Finishing of Titanium Alloy Using Novel Tool in Magnetic Field Assisted Finishing Process

2018 ◽  
Author(s):  
Anwesa Barman ◽  
Manas Das
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Normal Force ◽  
Tangential Force ◽  
Abrasive Particle ◽  
Initial Surface ◽  
Precise Control ◽  
Percentage Improvement ◽  
Finishing Process

Magnetic field assisted finishing process is a nanofinishing process which uses magnetic field for precise control of finishing forces. Magnetorheological fluid mixed with diamond abrasive particles in base medium of glycerol, hydrofluoric acid, nitric acid, and deionized water is used as the polishing medium. The novel tool is a magnet fixture made of mu-metal which is used to hold the magnet during finishing. In the present experimental study, finishing at a spot on flat titanium alloy is carried out to analyze the forces involved in the finishing. Normal force is the main force responsible for the indentation by the abrasive particle on the workpiece surface. Tangential force helps in removing indented material. The measured normal force and tangential force during the spot finishing are 3.285 N and 0.43 N, respectively. The final surface roughness achieved after spot finishing is 10 nm from initial surface roughness of 200 nm. The percentage improvement in surface roughness is 95%.

Study on Internal Magnetic Field Assisted Finishing Process Using a Magnetic Machining Jig for Thick Non-Ferromagnetic Tube

2011 ◽  
Vol 325 ◽  
pp. 530-535 ◽  
Author(s):  
Yan Hua Zou ◽  
Jiang Nan Liu ◽  
Takeo Shinmura
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Steel Tube ◽  
Machining Process ◽  
Surface Finishing ◽  
Stainless Steel Tube ◽  
Initial Surface ◽  
Rough Machining ◽  
Form Accuracy ◽  
Finishing Process

This paper describes an internal finishing process for thick non-ferromagnetic tube (10~20 mm in thickness) by the application of a magnetic field-assisted machining process using a magnetic machining jig (permanent magnet tool). In this study, a new automatic inner surface finishing system was developed, and to achieve smooth surface roughness and high form accuracy, a multiple-stage machining which contains of rough machining and precision finishing was carried out. Especially, in order to improve the form accuracy the rough processing time was made longer compared with the research in the past. The experiments were performed for a thick SUS304 stainless steel tube 10 mm in thickness. The results showed that surface-roughness and form accuracy were able to be improved greatly, the initial surface roughness of 4.9μmRa can be improved to 0.01 μmRa and the roundness of inside tube can be improved from 206 μm to13μm.

scholarly journals The polishing process of advanced ceramic balls using a novel eccentric lapping machine

2005 ◽  
Vol 219 (7) ◽  
pp. 493-503 ◽  
Author(s):  
J Kang ◽  
M Hadfield
Keyword(s):  
Surface Roughness ◽  
Removal Rate ◽  
Abrasive Particle ◽  
Initial Surface ◽  
The Novel ◽  
Advanced Ceramic ◽  
Finishing Process ◽  
Ball Surface ◽  
High Roughness ◽  
Lapping Machine

The finishing process of advanced ceramic balls can be divided into two steps. The first step is lapping in which most of the stock from the ball is removed at a higher material removal rate. The second step is polishing in which the required ball surface roughness, roundness, and dimensional and geometric accuracy are achieved. In polishing, the abrasive particle size is 1 μm, and the load and speed are lower than lapping. A novel eccentric lapping machine is used for polishing hot isostatically pressed (HIPed) silicon nitride balls. In the initial polishing stage, the polishing load is demonstrated as being most influential in the reduction of surface roughness value Ra. However, in the later polishing stages, the erosive process played a major role in the further reduction of Ra, although the high roughness peaks cannot be removed by erosive process alone. Experimental results also show that, in order to achieve desired surface roughness value, the initial surface quality of the upper plate should be reasonably high, and deep scratches on the ball surface from previous lapping processes should be avoided. The best polishing results achieved were surface roughness values of Ra of 0.003 μm and r.m.s. ( Rq) of 0.004 μm, ball roundness of 0.08–0.09 μm. This proves that the novel eccentric lapping machine is also suitable for polishing advanced ceramic balls.

scholarly journals Effect of Water-Based Nanolubricants in Ultrasonic Vibration Assisted Grinding

2018 ◽  
Vol 2 (4) ◽  
pp. 80 ◽  
Author(s):  
Mir Molaie ◽  
Ali Zahedi ◽  
Javad Akbari
Keyword(s):  
Surface Roughness ◽  
Specific Energy ◽  
Material Removal ◽  
Normal Force ◽  
Tangential Force ◽  
Process Efficiency ◽  
Multiwall Carbon Nanotube ◽  
Ultrasonic Vibrations ◽  
Mql Grinding ◽  
Water Based

Currently, because of stricter environmental standards and highly competitive markets, machining operations, as the main part of the manufacturing cycle, need to be rigorously optimized. In order to simultaneously maximize the production quality and minimize the environmental issues related to the grinding process, this research study evaluates the performance of minimum quantity lubrication (MQL) grinding using water-based nanofluids in the presence of horizontal ultrasonic vibrations (UV). In spite of the positive impacts of MQL using nanofluids and UV which are extensively reported in the literature, there is only a handful of studies on concurrent utilization of these two techniques. To this end, for this paper, five kinds of water-based nanofluids including multiwall carbon nanotube (MWCNT), graphite, Al2O3, graphene oxide (GO) nanoparticles, and hybrid Al2O3/graphite were employed as MQL coolants, and the workpiece was oscillated along the feed direction with 21.9 kHz frequency and 10 µm amplitude. Machining forces, specific energy, and surface quality were measured for determining the process efficiency. As specified by experimental results, the variation in the material removal nature made by ultrasonic vibrations resulted in a drastic reduction of the grinding normal force and surface roughness. In addition, the type of nanoparticles dispersed in water had a strong effect on the grinding tangential force. Hybrid Al2O3/graphite nanofluid through two different kinds of lubrication mechanisms—third body and slider layers—generated better lubrication than the other coolants, thereby having the lowest grinding forces and specific energy (40.13 J/mm3). It was also found that chemically exfoliating the graphene layers via oxidation and then purification prior to dispersion in water promoted their effectiveness. In conclusion, UV assisted MQL grinding increases operation efficiency by facilitating the material removal and reducing the use of coolants, frictional losses, and energy consumption in the grinding zone. Improvements up to 52%, 47%, and 61%, respectively, can be achieved in grinding normal force, specific energy, and surface roughness compared with conventional dry grinding.

Magnetic field assisted finishing process for super-finished Ti alloy implant and its 3D surface characterization

2018 ◽  
Vol 1 (2) ◽  
pp. 154-169 ◽  
Author(s):  
Anwesa Barman ◽  
Manas Das
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Process Parameter ◽  
Optimum Process ◽  
Roughness Parameters ◽  
Optimum Process Parameter ◽  
Joint Implant ◽  
3D Surface ◽  
3D Surface Roughness

Titanium alloy is used in medical industries due to its biocompatibility. Requirement of implant’s surface roughness and surface topography depends mainly upon its application. In the present study, application of titanium alloy is considered as femoral knee joint implant. The capability of magnetic field assisted finishing (MFAF) process and the polishing tool to provide implant worthy surface is analyzed here. In MFAF process, magnetorheological fluid mixed with abrasive powder in acidic base medium is used as the finishing medium. Characterization of the finished surface is carried out by analyzing 3D surface roughness parameters. The selected 3D surface parameters ( Sa, Spk, Sk and Svk) are considered due to their importance concerning load-bearing articulating surface of knee joint implant. Statistical design of experiment is used for experimental study and subsequently process parameters are optimized. From experimental investigation, the values of Sa, Spk, Sk and Svk are obtained as 11.32 nm, 15.82 nm, 6.51 nm and 41.15 nm, respectively, at optimum process parameter condition. The optimum process parameter values are 901 rpm of the tool, 0.60-mm working gap and 4.30 hrs of finishing time. The obtained values of 3D surface roughness parameters are in the nanometer range and the surface topography will render better wear properties, performance and longer implant life. Further confirmation experiments support the optimized values. The effect of individual process parameter on output responses is also analyzed.

Investigation of Grinding Force and Surface Integrity of IC10 in Creep Feed Grinding

2020 ◽  
Author(s):  
Jun-chen Li ◽  
Wen-hu Wang ◽  
Rui-song Jiang ◽  
Xiao-fen Liu ◽  
Huang Bo ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal ◽  
Normal Force ◽  
Removal Rate ◽  
Tangential Force ◽  
Grinding Force ◽  
Wheel Speed ◽  
Creep Feed Grinding ◽  
Creep Feed

Abstract The IC10 superalloy material is one of the most important materials for aero-engine turbine blade due to its excellent performances. However, it is difficult to be machined because of its special properties such as terrible tool wear and low machined efficiency. The creep feed grinding is widely used in machining IC10 superalloy due to the advance in reducing tool wear, improving material removal rate and surface quality. The creep feed grinding is a promising machining process with the advantages of high material removal rate due to large cutting depth, long cutting arc and very slow workpiece, and its predominant features might have significant influence on the grinding force and surface quality for the workpiece. Hence, it is of great importance to study the grinding force and surface integrity in creep feed grinding IC10 superalloy. In this paper, a series of orthogonal experiments have been carried out and the effects of grinding parameters on the grinding force and the surface roughness are analyzed. The topographies and defects of the machined surface were observed and analyzed using SEM. The results of the experiments show that the tangential force is decreased with the workpiece speed increasing. However, there is no significant change in tangential force with the increasing of grinding depth and wheel speed. The normal force is decreased with the workpiece speed increasing when the workpiece speed is less than 150 mm/min, but when the workpiece speed is more than 150 mm/min the normal force is increased tardily. Moreover, the normal force is increased sharply with the increase of grinding depth and is increased slowly with the increase of wheel speed. In general, the surface roughness is increased with workpiece speed and grinding depth increasing, while the trend of increase corresponding that of workpiece speed is more evident. The value of the surface roughness is decreased with wheel speed increasing. And it is found out that the main defect is burning of the IC10 superalloy material in creep feed grinding by energy spectrum analysis of some typical topography in this study.

scholarly journals Annular Surface Micromachining of Titanium Tubes Using a Magnetorheological Polishing Technique

Micromachines ◽  
2020 ◽  
Vol 11 (3) ◽  
pp. 314 ◽  
Author(s):  
Wanli Song ◽  
Zhen Peng ◽  
Peifan Li ◽  
Pei Shi ◽  
Seung-Bok Choi
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Field Strength ◽  
Magnetic Field Strength ◽  
Rotation Speed ◽  
Abrasive Particle ◽  
Internal Surface ◽  
Abrasive Particles ◽  
High Magnetic Field Strength ◽  
Titanium Alloy Tube

In this study, a novel magnetorheological (MR) polishing device under a compound magnetic field is designed to achieve microlevel polishing of the titanium tubes. The polishing process is realized by combining the rotation motion of the tube and the reciprocating linear motion of the polishing head. Two types of excitation equipment for generating an appropriate compound magnetic field are outlined. A series of experiments are conducted to systematically investigate the effect of compound magnetic field strength, rotation speed, and type and concentration of abrasive particles on the polishing performance delivered by the designed device. The experiments were carried out through controlling variables. Before and after the experiment, the surface roughness in the polished area of the workpiece is measured, and the influence of the independent variable on the polishing effect is judged by a changing rule of surface roughness so as to obtain a better parameter about compound magnetic field strength, concentration of abrasive particles, etc. It is shown from experimental results that diamond abrasive particles are appropriate for fine finishing the internal surface of the titanium-alloy tube. It is also identified that the polishing performance is excellent at high magnetic field strength, fast rotation speed, and high abrasive-particle concentration.

scholarly journals Investigation of a plain ball burnishing process on differently machined Aluminium EN AW 2007 surfaces

2018 ◽  
Vol 190 ◽  
pp. 11005 ◽  
Author(s):  
Marco Posdzich ◽  
Rico Stöckmann ◽  
Florian Morczinek ◽  
Matthias Putz
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Process Development ◽  
Fem Simulation ◽  
Initial Surface ◽  
Shape Deviation ◽  
Finishing Process ◽  
Path Distance ◽  
Burnishing Process

Burnishing is an effective chipless finishing process for improving workpiece properties: hardness, vibration resistance and surface quality. The application of this technology is limited to rotationally symmetrical structures of deformable metals. Because of the multiaxial characteristics, the transfer of this force controlled technology on to prismatic shapes requires a comprehensive process development. The main purpose of this paper is the characterization of a plain burnishing process on aluminium EN AW 2007 with a linear moved, spherical diamond tool. The method of design of experiments was used to investigate the influence of different machined surfaces in conjunction with process parameters: burnishing force, burnishing direction, path distance and burnishing speed. FEM simulation was utilized for strain and stress analysis. The experiments show, that unlike the process parameters the initial surface roughness as 3rd order shape deviation does not have a significant influence on the finished surface. Furthermore a completely new surface is created by the process, with properties independent from the initial surface roughness.

Mechanism Research on the Swirling Air Flow Compounded with Magnetic-Field Finishing

2008 ◽  
Vol 53-54 ◽  
pp. 51-55 ◽  
Author(s):  
Xiu Hong Li ◽  
Shi Chun Yang
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Air Flow ◽  
Abrasive Particle ◽  
Solid Particles ◽  
Two Phase ◽  
Machining Time ◽  
Machined Surface ◽  
Magnetic Field Coupling ◽  
Swirling Air Flow

A new finishing technology of the swirling air flow compounded with magnetic-field is advanced. Force acting on abrasive is analyzed by the action of airstream and magnetic-field coupling according to gas-solid particles two-phase flow. Finishing mechanism on the swirling air flow compounded with magnetic-field is illustrated, namely, burrs and microcosmic peak on the surface of workpiece are broken, grinded and cut via a great deal of abrasive particle impacting, microchipping and rolling machined surface. Unthreaded hole is experimented on the condition of changing magnetic induction intensity B and machining time t. Changing curve of surface roughness Ra along with time t is shown. Research indicates that machining time of the swirling air flow compounded with magnetic-field is short and machining efficiency is high. The longer machining time is, the smaller surface roughness Ra is and the better machining effect is.

Model establishment of surface roughness and experimental investigation on magnetorheological finishing for polishing the internal surface of titanium alloy tubes

2020 ◽  
pp. 1045389X2093009
Author(s):  
Zhen Peng ◽  
Wan-Li Song ◽  
Cui-Li Ye ◽  
Pei Shi ◽  
Seung-Bok Choi
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Internal Surface ◽  
Initial Surface ◽  
Polishing Process ◽  
Indentation Force ◽  
Rotation Motion ◽  
Surface Precision ◽  
Polishing Tool ◽  
Magnetorheological Polishing

A novel magnetorheological polishing process is devised to polish the internal surface of titanium alloy tubes. Under the magnetic field in polishing area between the internal surface of tube and polishing head, magnetorheological polishing fluid gets stiffened and acts as the polishing tool. In this process, rotation motion of tube and reciprocating linear motion of polishing head are carried out simultaneously resulting in helical motion trajectory of abrasive particles on workpiece surface. The finishing forces during magnetorheological polishing process including normal indentation force and shear force are analyzed and modeled. Based on the proposed model, final surface roughness Ra model is proposed to predict the polishing performance. Experiments are carried out to investigate the effect of polishing time and initial surface roughness Ra on polishing performance. The experimental results are compared with the model results, which are highly consistent. The results show a gradual growth of surface precision with polishing time and an augment of polishing efficiency with increasing initial surface roughness Ra.

Study on Sliding Friction Characteristics of Magnetorheological Elastomer - Copper Pair Affected by Magnetic-Controlled Surface Roughness and Elastic Modulus

2021 ◽  
Author(s):  
Rui Li ◽  
Di Wang ◽  
Xinyan Li ◽  
Ping-an Yang ◽  
Haibo Ruan ◽  
...  
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Elastic Modulus ◽  
Friction Coefficient ◽  
Sliding Friction ◽  
Volume Fraction ◽  
Coupling Effect ◽  
Initial Surface ◽  
Friction Characteristics ◽  
Adjustable Range

Abstract To optimize the online friction coefficient adjustment, it is necessary to study the parameter change features of the magneto-sensitive polymer and its influence on the friction characteristics under magnetic field. A series of isotropic magnetorheological elastomers (MREs) with different initial surface roughness were prepared, and a sliding friction platform with MRE - copper block pair was built to carry out magnetic-controlled friction characteristic experiment. Results show that the sliding friction coefficient of MRE decreases with the increase of the magnetic field, but the degree of reduction is quite different under different initial surface roughness and elastic modulus. When the initial surface roughness of MRE is between 0.5 - 2.5 μm and the ferromagnetic particles volume fraction is between 10% - 15%, its magnetic-controlled friction coefficient has the largest reduced value of 22.75%. Moreover, features of elastic modulus and surface topography under magnetic field were tested and analyzed. By combining with the single peak contact model and the friction binomial law, the relationship between the surface roughness and elastic modulus of MREs and the sliding friction force is deduced, and it is proved that the friction coefficient is affected by the coupling effect of surface roughness and elastic modulus. The magnetic-controlled elastic modulus is the key factor, which determines the overall downward trend of the friction coefficient of MREs. Magnetic-controlled surface roughness also plays an important role in the adjustable range of friction coefficient, and reducing the initial surface roughness can increase the magnetic-controlled friction coefficient adjustable range.

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