Finish Parameters Research Articles

Experimental investigation on magnetorheological fine finishing of EN-8 steel alloy mold surface for cylindrical plastic bottle caps

The cylindrical mold is a key element utilized in the manufacture of different cylindrical components for a wide range of applications in industries like automotive, aerospace, medical, and among others. Fine finishing of the cylindric mold with high surface integrity has several benefits such as good fits and tolerance, increased product quality, and high load-bearing capability for components. Recently, a cutting-edge rotating magnetorheological honing (RMRH) method based on permanent magnet tools was developed for the fine finishing of interior cylindrical surfaces with great productivity. Furthermore, many industrial real-time cylindrical molds need to be fine-finished with high productivity to enhance their functionality. To meet these requirements, the RMRH procedure could be the better option. Therefore, the RMRH process is investigated in the current study to finely finish the inner surface of the real-time EN-8 steel mold for plastic bottle caps. To determine how well the real-time EN-8 steel cylindrical mold could be fine-finished using the current process, the response surface technique was used to know the best finishing parameters. The significant % drop in parameters of the surface roughness profile ( Ra, Rz, and Rq) of the MR finished real-time EN8 mold surface is achieved as 86.05, 82.17, and 84.62, respectively, after 40 minutes of the RMRH process with the optimal parameters. Also, a considerable improvement in straightness is obtained as the final surface waviness on the inside cylindrical surface of the real-time EN8 mold for plastic bottle caps is decreased from an initial value of 120 nm to 40 nm. Further, circularity and surface morphology tests are carried out over the mold's finished inner surface. After providing the efficient MR finishing using the current process, results indicate that surface properties and functional efficacy of the internal surface of the real-time mold for producing plastic bottle caps have improved.

Magnetorheological fine finishing of steering rack bar for improving its functional operation

Fine-finished external cylindrical surfaces in automotive manufacturing parts are of great importance for improving their performance. A finely finished external surface of steering rack bar leads to a decrease in its response time. So, in this work, the rotating core-based magnetorheological (MR) finishing process has been performed on the external surface of steering rack bar to improve its performance. In this work, the process parameters have been optimized to fine-finish the current workpiece with minimized efforts. The optimum conditions of process parameters are depicted using full factorial central composite design (CCD) under response surface methodology technique. The maximum contribution to the response, i.e. % change in surface roughness value is found from current (15.28%) and rotational tool speed (8.66%). Using the optimum finishing parameters, the average surface roughness value of the steering rack bar external surface achieved was 30 nm from 550 nm with finishing time of 90 min. Also, the fine finishing of steering rack bar's external surface was confirmed by a comparative study of scanning electron microscopic and mirror images of initial and final finished surfaces conducted in this study. Thus, this study advocated that the current process can be beneficial for fine finishing of industrial components such as rocker arm shafts, vacuum pistons, and cylindrical punches.

Multi-response optimization of process parameters in nitrogen-containing gray cast iron milling process based on application of non-dominated ranking genetic algorithm

As a new, high-strength and clean cast iron material, nitrogen-containing gray cast iron has excellent properties and a wide range of application prospects. However, the excellent material properties of the material not only make the machinability challenging, but also the high efficiency and quality of the machining process is a pressing issue. Therefore, it is necessary to study the machining characteristics of nitrogen-containing gray cast iron to obtain the optimal machining parameters to enrich the research work on nitrogen-containing gray cast iron. In this paper, the machining characteristics of nitrogen-containing gray cast iron are systematically studied, and the effects of cutting parameters on milling force, milling temperature, and surface roughness are analyzed. And, based on the machinability assessment, the objective function weights under different production requirements are determined by using hierarchical analysis trade-offs, and an integrated optimization model based on non-dominated ranking genetic algorithm and hierarchical analysis (AHP) is proposed. The model outputs the optimal combination of milling parameters by inputting the cutting speed (vc), feed rate per tooth (fz) and cutting depth (ap), surface roughness and cutting efficiency as the objective functions. The experimental results show that cutting depth has the greatest effect on the cutting force and cutting speed has the greatest effect on the cutting temperature and the surface roughness. The passivation effect of nitrogen on the graphite tip resulted in an increase in both cutting force and cutting temperature. The parameter optimization results indicated that the optimized roughing parameters significantly improve the surface quality while machining efficiently; the optimized finishing parameters improve Ra by 23.53% while ensuring higher MRR, which can achieve efficient and high-quality machining under different production requirements and provide an experimental basis for practical engineering applications of nitrogen-containing gray cast iron.

Investigation on repairing 30CrMnSiNi2A steel with laser additive and subtractive hybrid remanufacturing technology

The 30CrMnSiNi2A ultra-strength steel features excellent comprehensive mechanical properties and has been widely used to manufacture structural parts such as the aircraft landing gear, the wing girder, the missile engine shell, etc. However, wear and defects are produced on the surface of these parts in the course of their long-term service. In this paper, a continuous-wave laser deposition and pulsed laser finishing hybrid technique was proposed to repair 30CrMnSiNi2A ultra-high strength steel. The microstructure and mechanical properties of 30CrMnSi2A alloy matrix, laser repairing and laser finishing parts were compared. Laser finishing parameters were optimized to further improve the surface properties of the repaired parts. The effect of different process parameters on the surface morphology, microstructures, micro-hardness and wear resistance was explored. The results revealed that the comprehensive surface properties of repair parts with an average surface roughness of 1.12 µm, a micro-hardness of 595.22HV and a wear rate of 4.78 × 10−3 mm3/N·m can be obtained with laser finishing. And, the surface roughness and wear rate were reduced by 64.96% and 27.68% respectively, and the micro-hardness can be improved 23.67% compared with the parts without laser finishing.

Taguchi’s design optimization for finishing of plane surface with diamond-based sintered magnetic abrasives

The magnetic field-assisted abrasive finishing parameters used in this study were the distance of the workpiece from the magnetic pole (D), amount of sintered magnetic abrasives (A), speed of rotation of the pole (R), grain size of the abrasive particles (S) and feed to the workpiece (F). The surface roughness percentage change (SRPC) and material removal rate (MRR) of the plane surface workpiece of aluminum are the response quantities. An orthogonal L16 array of the Taguchi method was constructed and is used in this study to analyze the influence of finishing parameters on the surface roughness percentage change of the workpiece. The analysis of variance (ANOVA) showed the extent to which finishing parameters are important. The experimental results showed that for SRPC, the best combination of levels for the given control factors is the distance of the workpiece from the magnetic pole (D) = 4 mm, the amount of sintered magnetic abrasive (A) = 16 g, the speed of rotation of the pole (R) = 600 rpm, the grain size of the abrasive particles (S) = 175 μm and the feed rate of the workpiece (F) = 1.5 m min−1. For MRR, the best combination of levels for the given control factors is the distance of the workpiece from the magnetic pole (D) = 4 mm, the amount of sintered magnetic abrasive (A) = 16 g, the speed of rotation of the pole (R) = 400 rpm, the grain size of the abrasive particles (S) = 175 μm and the feed rate of the workpiece (F) = 6.0 m min−1. The surface profiles and microscopic images of polished and unpolished workpieces show that the magnetic field-assisted abrasive finishing process is very effective in finishing aluminum surfaces.

Optimization of finishing parameters for magnetic compound fluid finishing (MCFF) of copper alloy

As an advanced finishing technology, magnetic compound fluid finishing (MCFF) is considered capable of achieving damage-free finishing of low-hardness materials such as copper alloys with appropriate finishing parameters. However, ignoring the influence of the material removal amount on the dimensional accuracy while optimizing finishing parameters may result in excessive material removal and a reduction in the workpiece’s dimensional accuracy. Thus, a novel finishing parameter optimization method considering dimensional accuracy is proposed in this paper. Firstly, the MCFF experiments are planned and carried out for modeling. Secondly, an MCFF model is established based on the integrated learning theory. The established model, with a prediction layer and a fusion layer, is a multi-layer neural network fusion model which can accurately predict the polished surface quality and material removal amount. Thirdly, the finishing parameters are optimized by the multi-objective particle swarm optimization algorithm, taking the effect of material removal on dimensional accuracy into account. Finally, the model’s prediction accuracy and the superiority of the optimized parameters are verified through experiments. The results demonstrate that the developed model can predict the finishing effect correctly, and a workpiece with high-quality polished surfaces and high dimensional accuracy can be obtained with the optimized finishing parameters.

Magnetorheological finishing of aluminium cylindrical roller for enhanced performance of printing operation

Aluminium is the most versatile engineering material for various industries, such as transport, machinery, metallurgy and printing. The aluminium cylindrical roller plays a significant role in the printing machine. In order to evenly distribute the pressure and for accurate tolerances roller needs to be perfect and uniformly finished. Owing to their ductility and lesser hardness, it is difficult to achieve uniform and fine finishing by conventional finishing methods. The rotary magnetorheological (MR) method is established to satisfy this requirement. The MR polishing fluid composition is initially analysed in order to obtain a fine finish. The central composite design was employed to optimize the finishing parameters. The batch gradient descent algorithm is used to validate the RSM optimization of process parameters. Batch gradient descent gives the mathematical model which validates the RSM mathematical model. The scan electron microscopy, reflectivity test and surface roughness profile check were carried out to track the surface texture and the cylindrical aluminium roller's ruggedness. The standard deviation test is performed to measure the uniformity of the finished surface and demonstrate that the uniformity of the finished surface which is increased. Geometric measurements are tested by the way of the surface waviness measurement. The results of earlier process parameters and with addition of reciprocation of work-part is compared and experimentation performed on 120 mm long and 25 mm diameter of the aluminium cylindrical roller with 30 mm length for each trial.

A feasibility study to analyze the behavior of heat settings on the cleaner production of knitted fabrics

Textile finishing gives textile materials their distinct appearance and aesthetic properties. One of the most critical stages of textile finishing is heat setting. Several factors of textile finishing are depend on heat settings. This study examines the behavior of heat settings and correlates the parameters on single jersey and pique knitted fabrics. In this case, the behavior of single jersey fabric and pique fabric are different in terms of target tumble dry GSM, and the tendency of single jersey cotton & viscose fabric in the grey stage is less width, high GSM, more shrinking characteristics, less bursting strength, and more yellowish than pique fabric. Following the heat setting changes for fabric width and GSM based on light, medium, and dark colors; all heat-dependent finishing parameters, such as fabric weight, pilling, spirality, dimensional stability, bursting strength, and color strength, are systematically analyzed based on industrial applications. The target GSM are set for cotton fabric is 190 and viscose fabric is 210. The result of the GSM are found in the almost in the same range in between 190 and 210. The other properties of fabric after heat settings are pilling 4–5, dimensional stability change (lengthwise 0.86–5.71 and widthwise 0.86–5.43), spirality (−2.5 to +2.1), bursting strength (162.4–450.4 kN/m2), and color strength (increased an average 5%). As a result, analyzing several influential factors based on heat setting provides a clear concept for the cleaner industrial production of knitted fabrics.

Experimental investigation on the effect of barrel finishing processes on surface integrity of 18CrNiMo7-6 carburized rollers

There has been growing interest in enhancing the properties of machine components to improve their reliability in recent years. Surface barrel finishing is one of the most widely used surface processes to decrease the surface roughness of components and improve mechanical properties. However, the effect of barrel finishing parameters on surface integrity such as residual stress and hardness distribution is still unclear, which needs an in-depth understanding. This study experimentally investigated the effect of different barrel finishing media and finishing time on the surface integrity including surface morphology, residual stress, microhardness and microstructure of 18CrNiMo7-6 carburized rollers. Experiment results demonstrate that the surface roughness Sa can be decreased to less than 0.2 μm with the surface barrel finishing, and the surface compressive residual stress (SCRS) can be increased by 500 MPa compared with shot peening process. In addition, the surface microhardness increased by 20 HV and the grain size of the surface layer was refined. The improvement of the surface integrity should be of interest for engineers when designing against rolling contact fatigue.

Application of vortex air cooling in automated angle grinder: effects on surface integrity – exploratory study

Framatome has developed an automatic grinding bench to reproduce manual dry grinding applied in workshop. This surface finish operation generally leads to tensile residual stress in welding materials. The current study proposes to investigate the effect of vortex air cooling as an innovative option for the lowering of surface effects induced by dry grinding.Grinding assisted by vortex cooling was tested on AISI 304L and Alloy 690 (UNS N06690). The effect of cooling assistance on microstructural properties of these materials was evaluated using microhardness, XRD residual stress measurements, roughness, SEM & EBSD characterizations. The results suggest that vortex cooling has a lower effect on surface finish parameters of stainless steel 304L than those of alloy 690.

Analysis of surface finish and residual stresses with shot peening on cylindrical specimens

Abstract Machining of cylindrical metal pieces effects the surface parameters due totool and type of contact. Due to the surface contact of the tool with the work material, the surface texture may deteriorate depending on the machining parameters applied. In order obtain good surface finish, the tool and machining parameter are the major considerations. In this paper shot peening was considered to determine good surface finishing. Cylindrical rods of different materials were considered for obtaining good surface finishing using the shot peening process. The nozzle was turned to an angle of 10 degrees from the principal axis. The blast pressure was controlled to obtain required surface finish. The surface hardness obtained after shot peening was measured. The residual stresses induced from the depth of the surface are determined and compared for various peening pressures.

Genetic evolutionary approach for surface roughness prediction of laser sintered Ti–6Al–4V in EDM

Abstract Additive Manufacturing (AM) methods, in the field of production, are increasing rapidly. In particular, the use of Ti alloys has an important role in AM methods. The major disadvantage of AM methods is low surface quality of the manufactured parts. Therefore, parts produced using AM methods need subsequent surface treatment. Electro Discharge Machining (EDM) is one of the nontraditional machining methods, which can be used to improve the surface quality with appropriate parameters. In this study, EDM was investigated to improve the surface quality of sintered Ti–6Al–4V alloy by using 160 different finish parameters. It was observed that Current (I) has a notable effect on surface roughness showing that best surface quality is achieved with low current values, which is under R a = 2 µm. To estimate the final result of EDM, roughness values obtained from the experiments were modeled by using the Genetic Expression Programming (GEP), and a mathematical relationship between the obtained roughness values and EDM parameters was proposed. As a result of 830,900 iterations, GEP model created can estimate the final surface roughness of the parts with 84% accuracy.

Correlating tool wear and surface integrity of a CNC turning process using Naïve based classifiers

Surface finish is an important phenomenon in hard turning. There are many factors which can influence the finishing of a product. Literature review reveals that substantial research has been performed on hard machining, still relationship of tool wear and surface finish parameters like [Formula: see text] and [Formula: see text] is not established as the process is so dynamic and transient in nature. As a result, most of the responses like tool wear, surface integrity parameters, cutting force, and vibration are random in nature. In this investigation, Topic Modelling (TM), a relatively new topic particularly used in machine learning is applied to determine a particular stage of tool wear. Tool wear is divided into three distinct groups namely initial stage (IS), progressive stage (PS), and exponential stage (ES) from a number of experimental observations. Then, surface parameters namely [Formula: see text] and [Formula: see text] are measured. A probabilistic model consisting of tool wear and surface parameters is developed using Naïve based classifier. This model is capable to predict a particular stage of tool wear given randomly selected values of [Formula: see text] and [Formula: see text] To validate this probabilistic model, an alternative machine learning method called multinomial logistic regression is used. Each of this method indicates that the tool has reached to exponential stage when [Formula: see text] and [Formula: see text] =. [Formula: see text]

Cryogenic turning of Hastelloy C-22

In the present investigation, wear of the PVD coated TiAlN carbide insert and the surface finish parameter of the machined Hastelloy C-22 surface have been studied under dry and cryogenic turning. Machining tests were carried out at cutting velocity range of 0.7 - 2.1 m/s, feed of 0.11 and 0.13 mm/rev and a depth of cut of 1 mm. It has been found that the roughness parameter (Ra) was reduced to a maximum of 54 % in cryogenic turning using liquid nitrogen over dry turning. Cryogenic liquid nitrogen cooling enabled substantial improvement in cutting performance of inserts in terms of reduction in wear rate by cooling and lubricating effect at the sources of heat, sliding and interacting regions

In-process characterization of surface finish in cylindrical grinding process using vibration and power signals

Grinding being a finishing process, the quality of the ground surface is one of the most important performance evaluation parameters. Grinding process being highly stochastic in nature, surface finish is affected by many factors and experimental evaluation of each factor is a tedious task. In this study, the in-process signals collected using various sensors attached to a cylindrical grinding machine such as Accelerometer and Power are processed, and their features are correlated with a surface finish parameter. This correlation is modelled using gradient boosting algorithm and surface finish obtained is predicted and validated on an industrial application.

New Magnetic Abrasive Finishing for Alumina Ceramic Plane Using Alternating Magnetic Fields

In this paper, we propose a new plane magnetic abrasive finishing method, applicable to planes, that uses the alternating magnetic fields to solve problems such as the easy deformation and poor recovery of a magnetic brush in conventional magnetic abrasive finishing method. Compared with the magnetic brush used in conventional magnetic abrasive finishing, that in the new method can stably shape a workpiece under an alternating magnetic field. To determine the optimal finishing parameters, we focused on studying the effects of spindle rotational speed, size of diamond particle, and frequency of alternating magnetic field on the finishing surface. Then, according to the obtained optimal finishing parameters, multi-stage finishing experiments were performed with the new method. The results show that surface roughness can be improved from 230 nm Ra to 19 nm Ra in 60 min with the proposed method.

The Impact of Laser Radiation on Polypropylene Molded Pieces Depending on Their Surface Conditions

The article presents an analysis of the impact of a laser beam interaction (Nd: YVO4) with selected operational parameters on the quality of graphical marks obtained on the surfaces of polypropylene-molded pieces with different surface textures (variable parameters of the surface layer). Polypropylene test specimens were produced by injection using the original injection mold, which allowed for the obtainment of products with variable surface finish parameters determined by the surface condition of the forming cavity. The presented relationship between the parameters of laser performance, the texture of a molded piece surface, the molded piece’s color, and types of masterbatches supporting the marking process allows for the assessment of the efficiency of graphic symbol application by laser marking. The original evaluation criteria for the conducted process were adopted.

FEM simulation-based cutting parameters optimization in machining aluminum-silicon piston alloy ZL109 with PCD tool

The Johnson-Cook (JC) constitutive model was utilized to simulate the processing of Al-Si piston alloy ZL109 to obtain the optimal finishing parameters in polycrystalline diamond (PCD) tool, and studied the machining quality of ordinary-turning under the optimized cutting parameters. PCD is brittle, so it is difficult to manufacture orthogonal blades and is easy to break and high cost. We have adopted ordinary-turning quality to verify simulation results. Effect of cutting parameters on residual stress, cutting force and temperature was investigated through simulation, meanwhile, effect of cutting parameters on surface roughness and residual stress was analyzed by experiments. It indicates the verification method is practicable, and residual stress, cutting force and temperature are the smallest in simulation, and the experimental values of surface roughness and residual stress are also the smallest under the optimal cutting parameters, which can guide the cutting parameters selection to obtain higher machining quality.

Crease Resistance Finishing Optimization of Citric Acid and Fibroin Solution for Cotton Fabrics

ABSTRACT Wrinkling effect in cellulose fiber–made fabrics has a major setback for their use as apparels necessitating the use of crease resistance finish. For a while, formaldehyde-based-finished dimethyl dihydroxy ethylene urea has been used as crease resistance finish. DMDHEU finished fabric will releases formaldehyde during its application, that affects both user’s health and the environment. This research optimized citric acid (CA) and silk fibroin solution as a crease resistance finishing agent. CA was identified as a non-formaldehyde-based cross-linking agent but causes yellowing in cotton fabrics. To steer clear of this, silk fibroin solution was added with CA to increase the crease resistant in avoiding yellowing of the fabric caused by CA. The optimum combination of the processing parameters obtained was 6% silk fibroin solution, 30 g/L of CA, and 6% sodium dihydrogen phosphate, at a finishing bath at pH of 5.5 with curing temperature of 150°C. These optimized finishing parameters achieved a dry crease recovery angle of 252° while obtaining an 84% tensile strength retention, 96% tearing strength retention, and 75 WI (93%) whiteness index.

Prediction of the tactile comfort of fabrics from functional finishing parameters using fuzzy logic and artificial neural network models

This paper aims to predict the hand values (HVs) and total hand values (THVs) of functional fabrics by applying the fuzzy logic model (FLM) and artificial neural network (ANN) model. Functional fabrics were evaluated by trained panels employing subjective evaluation scenarios. Firstly, the FLM was applied to predict the HV from finishing parameters; then, the FLM and ANN model were applied to predict the THV from the HV. The estimation of the FLM on the HV was efficient, as demonstrated by the root mean square error (RMSE) and relative mean percentage error (RMPE); low values were recorded, except those bipolar descriptors whose values are within the lowermost extreme values on the fuzzy model. However, the prediction performance of the FLM and ANN model on THV was effective, where RMSE values of ∼0.21 and ∼0.13 were obtained, respectively; both values were within the variations of the experiment. The RMPE values for both models were less than 10%, indicating that both models are robust, effective, and could be utilized in predicting the THVs of the functional fabrics with very good accuracy. These findings can be judiciously utilized for the selection of suitable engineering specifications and finishing parameters of functional fabrics to attain defined tactile comfort properties, as both models were validated using real data obtained by the subjective evaluation of functional fabrics.