Abstract
Magnetic abrasive finishing (MAF) is a fast, high efficiency and high-precision polishing method on the surface machining of the metals. Furthermore, MAF also can be utilized to polish the stainless tubes in industrial applications; however, stainless tubes are often a non-magnetic material that makes it difficult for the magnetic field line to penetrate into the stainless tubes, thus reducing the magnetic forces in the inner tubes polishing. That is why stainless tubes are not easy to finish using traditional MAF. Therefore, magnetic finishing with gel abrasive (MFGA) applies gels mixed with steel grit and abrasives that were developed to improve the polishing efficiency and surface uniformity of the steel elements. In this study, a guar gum or silicone gel mixed with steel grit and silicon carbides are used as the magnetic abrasive gel to polish the stainless inner tubes. A DC motor was used to control the rotation speed of the chuck and an AC induction motor connected with an eccentric cam to produce the reciprocating motion of the workpiece were utilized to finish the inner surface of stainless tubes in the polishing process. The parameters of abrasive concentration, abrasive particle sizes, rotation speeds of motor and electric currents were used to investigate the surface roughness and the removal of materials from the stainless tubes. The experimental results showed that since guar gum had better fluidity than the silicone gel did, guar gum created excellent polishing efficiency in MFGA. Furthermore, the surface roughness of the stainless tube decreased from 0.646 μm Ra to below 0.056 μm Ra after processing for 30 min with the parameters of current 3A, gel abrasive with guar gum, rotational speed 1300 rpm and vibration frequency 4 Hz.
Highlights
With the advancement of processing technology, the development requirements of industrial related equipment and components need to be extremely precise, especially in industries such as biomedical technology, electronics, aerospace and optics
Magnetic fields can create the radial forces to press the abrasive grains on the workpiece surface, so the mirror-like surfaces of the product can be obtained during the alternating motion in magnetic abrasive finishing (MAF) and the burrs or the recasting layers are to remove by this process
To achieve the stated objective, material weight measurements and surface roughness measurements were taken to demonstrate the increase in material removal (MR) and roughness improved rate (RIR) and the roughness uniformity after the magnetic finishing with gel abrasive (MFGA)
Summary
With the advancement of processing technology, the development requirements of industrial related equipment and components need to be extremely precise, especially in industries such as biomedical technology, electronics, aerospace and optics. A magneto-rheological abrasive flow finishing (MR-AFF) technique [4,5,6] was developed to make the precise elements; this method utilized a magnetic field to constrain the permeability fluid abrasive to finish the surface of workpieces. MAF is an excellent method to finish the inner or outer surface of the tubes, the mirror surface machining of the complex mold, it can deburr and remove the recasting layers by the heat machining [7,8,9,10]. Magnetic fields can create the radial forces to press the abrasive grains on the workpiece surface, so the mirror-like surfaces of the product can be obtained during the alternating motion in MAF and the burrs or the recasting layers are to remove by this process. Singh et al [15]
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