Abstract
Ultrasonic assisted magnetic abrasive finishing process (UAMAF) is a precision manufacturing process that results nano-scale level finish in a part. Normal force on a particle helps indenting the particle in the work surface whereas horizontal force provides finishing torque that in-turn helps the particle to perform micro-machining. Better understanding of the effect of these forces on material removal and wear pattern of the work-piece necessitates mathematical modeling of normal force and finishing torque and subsequently its validation with experimental results. In the present study, single particle interaction concept is considered to develop a model which is subsequently applied for all active particles of magnetic abrasive powder (MAP). Separation point theory is applied to consider the effect of ploughing below a critical depth and shearing above that depth. Normal components of shearing and ploughing forces are considered for calculating normal force and horizontal components of shearing and ploughing forces are taken to calculate finishing torque. Johnson-Cook model is applied to calculate shearing strength of the work material during UAMAF. The impact of ultrasonic vibrations is considered while calculating strain rate. Images are taken with the help of scanned electron microscope and atomic force microscope to study the material removal and wear mechanism during UAMAF process. Predicted values of force and torque model are validated with the experimental values.
Highlights
Latest trends in manufacturing sector have opened new research avenues for extensive applications of advanced engineering materials, high quality geometrically complex parts and requirement of nano level finishing
Finishing experiments were performed on SS304 work material and the material removal and wear pattern during Ultrasonic assisted magnetic abrasive finishing (UAMAF) process were studied
Comprehensive analysis of surface integrity of the workpiece by the UAMAF process was done with the help of scanned electron microscopy (SEM) and atomic force microscopy (AFM) micrographs
Summary
Latest trends in manufacturing sector have opened new research avenues for extensive applications of advanced engineering materials, high quality geometrically complex parts and requirement of nano level finishing. Kala et al [7] performed experimental study on the finishing forces on paramagnetic work-piece in double disk MAF process All these researchers [1,5,6,7] considered shearing effect while developing the theoretical models and did not take ploughing phenomenon into consideration. Literature review reveals that researchers [1,5,6,7] carried out theoretical and mathematical studies of MAF/UAMAF process considering shear but not plough effect These researchers used mechanically mixed powder for their experimental work. It is concluded that MAF/UAMAF process requires an extensive theoretical study and development of a mathematical model considering both shearing and ploughing effects together to understand the micro-cutting mechanism and wear pattern. Experiments were performed to validate the mathematical models and to understand the contribution of wear mechanism on the surface finish
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