Abstract
Based on the mechanism of magnetic abrasive finishing, the 7075 aluminum alloy (Al7075) was used in the experimental study. In order to improve wall surface quality and to remove the edge burrs of the hole, a novel magnetic abrasive finishing process was proposed. First, the radial magnetizing pole for the inner surface finishing process was confirmed. The evaluation of magnet spinning speed, abrasive mesh, and abrasive filling amount on the diameter deviation of the hole and surface roughness of the inner wall was studied. According to the characteristics of magnetic abrasive finishing process, Taguchi’s method was used to carry out the test. Through the analysis of variance, the best process parameters were determined and verified. The inner surface roughness was further decreased and the surface morphology was more uniform after finishing process. Second, the edge burr removal process of the hole exit was also studied, and the geometry of the burrs was measured before and after the magnetic abrasive finishing process. The results show that the burrs were significantly removed and the burr removal efficiency was improved by 33.3% compared with the conventional magnetic abrasive finishing process. Finally, the improved magnetic abrasive finishing process is an effective method in improving finishing quality of the Al7075 holes.
Highlights
Al7075 has been widely used as a key material in the aerospace field
This study aimed to improve the quality of inner wall and burr removal efficiency at the edge of the hole, and the surface roughness and micro-morphology will be studied based on magnetic abrasive finishing (MAF) process
The value of the surface roughness of the inner surface of the hole reduced from Ra = 2.5 mm to about Ra = 0.7–1.0 mm
Summary
Al7075 has been widely used as a key material in the aerospace field. Ali et al.[1] noted that the advancements of the 7000 series of Al alloys, such as fatigue strength and fracture toughness, have paved their way in replacing steel. Efkolidis et al.[2] mentioned that Al7075 has good performance such as low density, moderate strength, easy forming process, and corrosion resistance. It always has deterioration layer in drilling process, heat-affected layer, processing grains or burrs in the inner surface, or edge burrs of the hole entrance and exit, no matter what special or traditional techniques are adopted to manufacture holes. Niknam and Songmene[4] and Kwon et al.[5] thought that burrs can remain stuck on the part, possibly leading to several problems, and seriously affect the assembly accuracy and the life of the workpiece.
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