Interplay of Process Variables in Magnetic Abrasive Finishing of AISI 1018 Steel Using SiC and Al2O3 Abrasives

Mohammad Uddin,Romeo Marian,Vincent Santos

doi:10.3390/jmmp3020029

Mohammad Uddin, Romeo Marian + Show 1 more

Open Access

https://doi.org/10.3390/jmmp3020029

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Abstract

This paper investigates the underlying interplay between the key process parameters of magnetic abrasive finishing (MAF) in improving surface quality. The five process parameters considered were the working gap, rotational speed, feed rate, abrasive amount, and abrasive mesh when MAFed independently with two abrasive particles—SiC and Al2O3. A series of experiments were conducted with an in-house built MAF tool. Based on the main effect results, a model predicting roughness reduction was developed. Results show that surface quality improvement and the underlying dominant process parameters seem unique to the abrasive type used. When MAFed with SiC, the abrasive quantity and rotational speed influence the most. On the other hand, when MAFed with Al2O3, the trend is different to SiC, i.e., the abrasive mesh size and the working gap are dominant. The prediction model was well validated by independent experiments, indicating its accuracy in estimating and optimizing the process outcome. MAF is a simple process with a complex interplay between parameters. This is very crucial when abrasive type, size, and amount to be used are concerned, which warrants a deeper investigation in terms of underlying dynamics, interactions, and the deformation of abrasive, magnetic, and workpiece materials.

Highlights

Surface finish is regarded as one of the key precursors of functional integrity of many high-end mechanical components
It was shown that magnetic abrasive finishing parameters, such as finishing gap, speed, and feed, affect micro material removal and surface finish
Results of pooled analysis of variation (ANOVA) of ∆Ra for magnetic abrasive finishing (MAF) with SiC and Al2 O3 are summarized in Tables 5 and 6, respectively

Summary

Introduction

Surface finish is regarded as one of the key precursors of functional integrity of many high-end mechanical components. In this regard, as an alternative, magnetic abrasive finishing (MAF). SiC and Al2 O3 particles are commonly used in finishing of various materials including metal, plastic, and ceramics. These particles attracted significant attention in terms of their use in MAF, new types of abrasive particles, e.g., carbon nanotubes, are being explored by researchers [7]. While unbonded particles are suitable for high material removal, bonded ones tend to produce a better finish [8]. While the efficacy of bonded and unbonded MAF systems is studied, the conflicting conclusions are still often reported, reiterating that, with a combination of

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