A trend toward abrasive nano finishing of plane surfaces with magnetic field energy

Abstract

AbstractIn new developed parts, roughness has become an effective parameter and influences the performance of the entire system. Manufacturing of parts with fine surface finish have been a target for many advanced industries. Sometimes, it is difficult to reach highly polished surface quality by conventional methods. One of the newly introduced methods for obtaining fine finished surfaces is nano‐scale finishing with abrasive particles in magnetic fields. It is a relatively new finishing process that can be used to produce efficiently shiny surface quality for certain parts [1]. In this process, the cutting movement is provided by the magnetic field energy of permanent or electric poles. Magnetic abrasive particles (MAPs) are used to remove chips, and polish the work‐piece surface [2, 3]. The work‐piece is in the shape of a flat plane. An apparatus has been designed and made for machining the upper face of the plane. Nd‐Fe‐B magnets are used to establish the magnetic field. An NC machine is applied to create the rotational movement of MAPs in the horizontal plane and maintain the vertical position accurately. Various experiments have been designed to specify the machining characteristics of the MAF process. In these experiments different effective conditions are determined. Permanent magnets with 1.2 T magnetic flux density are used as magnetic poles. Homogeneous mechanical mixture of abrasive powder (Silicon Carbide) and ferromagnetic iron particles are used as the MAPs. The experimental setup was designed for finishing the aluminium alloy AA–6061. Test results indicated that the finishing parameters affect the material removal rate (MRR) and surface roughness.