Abstract

This research aims to present a novel approach in magnetic abrasive finishing to improve its potential for creating different finishing patterns in the free-form surface using no special fixtures or tool machines to minimize the complexity of the process. The key point of this idea is that magnetic abrasive particles can move in special patterns by transfer magnetic fields (similar to a magnetic train moving on a magnetic rail) and create the desired polishing patterns on the surface simultaneously. The coils are placed under a thin plate; then, a flexible magnetic path is created by a special arrangement of magnetic coils; after that, the coils are turned on and off in turn, and the magnetic abrasive particles move in the created path and abrasive the surface. The continuous movement of magnetic abrasive particles under the magnetic field will abrade the thin sheets’ surface. The tests were performed on copper sheets with a thickness of 1 mm. Experimental parameters include electric current (0.25, 0.5, and 0.75 A), speed of turning on and off of the coils (speed of magnetic abrasive particle movement) (20, 30, and 40 mm/s), and process time (1, 2, and 3 h). The experiments were performed on L-shaped and free-form sheets. The results show that using a transmission magnetic field in the MAF (TMAF) makes it easy to create different surface roughness patterns in different directions simultaneously. While in one part of the L-shape the electric current is 0.25 A, the surface roughness is around 0.90 µm, in the other part, where the electric current is 0.75 A, the surface roughness is around 0.49 µm. Meanwhile, TMAF makes it possible to finish a free-form surface with no special fixtures. Moreover, there is a direct relationship between the change in the surface roughness and the electric current and process time.

Highlights

  • 1.1 MAF principleThe magnetic abrasive finishing (MAF) process was introduced by American and Russian researchers[1]

  • The coils are placed under a thin plate, a flexible magnetic path is created by a special arrangement of magnetic coils, after that, the coils are turned on and off in turn, and the magnetic abrasive particles move in the created path and abrasive the surface

  • The results show that using a transmission magnetic field in the MAF (TMAF) makes it easy to create different surface roughness patterns in different directions simultaneously

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Summary

Introduction

The magnetic abrasive finishing (MAF) process was introduced by American and Russian researchers[1]. In the MAF technique, cutting tools consists of iron and abrasive particles[3]. To apply the MAF technique, a machine tool, abrasive particles, medium composition, and process settings are essential. In many types of research, conventional production machines such as lathe and milling have been utilized for the MAF process according to the workpiece geometries. In the case of MAF for flat surface, by using milling machines, the magnetic tool is chucked in the spindle and rotated which the magnets are placed a few millimeters above the parts. A number of researchers introduce special MAF machines to finish complex workpieces by developing freecurved tools which are inserted into the spindle or using robot arms[5]. While few researches utilize permanent magnets[6], others prefer to use electromagnetic inductor which consists of an inductor of steel road wrapped with a coil of wire[7]

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