Magnetic Abrasive Finishing Method Research Articles

Experimental investigation of aluminium 2024 alloy using cylindrical magnetic abrasive finishing process

In super finishing operations, the magnetic abrasive finishing (MAF) method is being researched as the Predominant finishing method. A cylindrical MAF (CMAF) method that was developed internally has undergone experimental investigation to improve the surface qualities of the aluminium 2024 alloy (Al 2024). For the machining process, a mixed abrasive of Al2O3 and SiC was utilized. Variable process factors for the experimental investigation include voltage, speed, and the percentage of abrasives. Based on results, the surface finish of the workpiece had improved to 94.12 % from its initial surface finish with a maximum of 11.5 mg of metal removed from the surface. Nevertheless, throughout the experimentation, the temperature that develops on the work surface as a result of the abrasives' shearing action is less than 57 °C.

Surface modification of wire-EDMed Ti6Al4V alloy by ultrasonic assisted magnetic abrasive finishing technique

In this study, it is aimed to remove the white layer formed on the surface of Ti6Al4V alloy as a result of Wire-Electro Discharge Machining by Magnetic Abrasive Finishing method. In the study, specimens were machined with W-EDM method under constant conditions and were machined at different levels of machining time, abrasive size, the number of revolutions and magnetic field parameters in UAMAF and MAF method. In the study in which Taguchi L18 experimental design was used, a total of 36 experiments were performed for MAF and UAMAF methods. The machined samples were examined by SEM and changes in white layer thickness were recorded. Statistical effects of processing parameters on white layer thickness were determined by the ANOVA method. As a result of the study, it was determined that the white layer thickness could decrease by 84% and 89% for the MAF and UAMAF methods, respectively. It has been also determined that ultrasonic support has a positive effect of 13.45% on average.

Study the Effect of Inductor and Pole Geometry on the Surface Roughness and Material Removal Weight Using Magnetic Abrasive Finishing Method

The traditional finishing method cannot keep up with recent labor market requirements, solve the problem of increasing production, improve the surface roughness and accuracy of workpiece. While the unconventional magnetic abrasive finishing (MAF) method has shown as a promising technique that can be used to finish complicated surfaces. MAF finishes metals, alloy, ceramic, and other materials that are difficult to finish by other processes. In another word, MAF improves the quality of surfaces with low cost.
 This paper focuses on optimize and study the effect of inductor and pole geometry (radius of hole, angle of core, angle of pole, radius of pole), on (surface roughness (Ra) and material removal weight (W)) and fined the optimum values that increase the efficiency of MAF method. Taguchi method employed to study the influence of geometry parameters and find the optimum values using orthogonal array L9. The results conclude that the most significant factor that effects change in surface roughness (ΔRa) and material removal weight(ΔW) are radius of the hole (R) and angle of core (α), respectively.

Parametric studies on finishing of inconel 718 flat surfaces with chemically assisted magnetic abrasive finishing process

With progressions in technological advancements, many materials that can withstand adverse conditions in their working environment are in high demand. Inconel 718 is one of few such materials which is widely used for various industrial applications such as nuclear industries, marine applications, solar power stations, heat exchanger tubing etc. But due to its superior attributes, Inconel 718 is quite hard to finish with traditional machining/finishing processes. A hybrid finishing process: Chemically assisted magnetic abrasive finishing method can be employed to finish the flat surface of Inconel 718. Three major process factors: Processing time, Chemical concentration and weight percentage of abrasives have been selected. Experiments have been designed using Response Surface Methodology (RSM). Effect of these three selected process parameters on Percentage Improvement in Surface Finish (PISF) has been analyzed with ANOVA. Scanning Electron Microscopy (SEM) is also utilized to observe the effects of process factors on surface microstructure. Results indicate that Chemically assisted Magnetic abrasive finishing can be successfully implemented to finish flat Inconel 718 work surfaces and parameters like Processing time, Chemical concentration and Weight percentage of abrasives have significant effect on PISF.

Study on a New Kind of Magnetic Abrasive Finishing by Using Alternating Magnetic Field for Ultra-Precision Plane Finishing

In this study, a new plane magnetic abrasive finishing method by using alternating magnetic field has been proposed to solve the problems such as the easy deformation and poorly restored of the magnetic brush in traditional magnetic abrasive finishing. Compared with the magnetic brush in traditional magnetic abrasive finishing, the magnetic brush can keep a relatively stable shape to finish the workpiece under the action of alternating magnetic field. In this paper, the variation of the finishing force in the alternating magnetic field is analyzed theoretically. In addition, in order to get the ultra-precision plane surface, the influence of the size of the magnetic particles, the size of the GC particles, and the frequency of the AC power on the finishing characteristics has been studied. The best experimental results show that the surface roughness of the workpiece is improved from 38 nm Ra to 6.33 nm Ra.

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.

Development of a New Ultra-High-Precision Magnetic Abrasive Finishing for Wire Material Using a Rotating Magnetic Field.

In this paper, we propose a new ultra-high-precision magnetic abrasive finishing method for wire material which is considered to be difficult with the existing finishing process. The processing method uses a rotating magnetic field system with unbonded magnetic abrasive type. It is believed that this process can efficiently perform the ultra-high-precision finishing for producing a smooth surface finish and removing a diameter of wire material. For such a processing improvement, the following parameters are considered; rotational speed of rotating magnetic field, vibration frequency of wire material, and unbonded magnetic abrasive grain size. In order to evaluate the performance of the new finishing process for the wire material, the American Iron and Steel Institute (AISI) 1085 steel wire was used as the wire workpiece. The experimental results showed that the original surface roughness of AISI 1085 steel wire was enhanced from 0.25 µm to 0.02 µm for 60 s at 800 rpm of rotational speed. Also, the performance of the removed diameter was excellent. As the result, a new ultra-high-precision magnetic abrasive finishing using a rotating magnetic field with unbonded magnetic abrasive type could be successfully adopted for improving the surface roughness and removing the diameter of AISI 1085 steel wire material.

Magnetic Abrasive Deburring Technology for Blanks

Blanks made from sheet steel or other materials have burrs on their edges. The burrs are formed on the blanks at cutting down or processing of them by cutting tools. Removing of the burrs requires a lot of manual work. Frequently the blanks have small rigidity, and it especially complicates removal of the burrs. This article describes intensification of the magnetic abrasive finishing method (MAF) with a goal to eliminate the manual deburring and to raise productivity of deburring on the flexible blanks. The study goal was achieved by optimization of MAF conditions and a of the work area geometrical form.

磁気研磨ブラシによる研磨機構の解明

Nowadays, a free-form surface, such as molding die surface, is required to be finished by reducing the environmental burden. Therefore, a novel polishing technology is needed with a less abrasive slurry,for the reduction of which a magnetic abrasive finishing method is attracting attention. However, it is well known that a conventional magnetic polishing method is unstable and insufficient to obtain the required surface roughness. In the present paper, we discuss the reasons causing instability in conventional magnetic polishing. We systematically investigate the magnetic pressure distribution characteristics and measure the pressing force distribution of the magnetic brush during machining. Furthermore, to observethe impact of an iron particle shape on the pressing force, we used steel balls (steel-ball brush) and abrasive slurry. Moreover, we compared this brush with a brush that uses iron powder paste (employed in the conventional magnetic polishing method). Thus, we determined the possibility of the wide range control of the pressing force by changing the shape and size of the magnetic material. The setting of the approach conditions should be sufficient because it could deteriorate the shape accuracy through very high pressure.

607 磁力を用いた自律的自在変形工具のみがき特性に関する研究(OS3 先進製造技術(4),研究討論セッション)

Currently, when performing a finishing on a flat or curved surface by using magnetic abrasive finishing method, it is difficult to perform a stable finishing, and unevenness is also occurring on the surface of workpiece. It can be attributed to large dispersions which affect the brush. In the present study, we attempt to use the steel-balls to reproduce the processing which by commercial abrasive paste for clarifying what caused the unevenness. Further, we proposed the new polishing tool by utilizing the characteristic of brush shape that following the shape of the processing site, and clarifying its polishing mechanism.

Hybrid tool with both fixed-abrasive and loose-abrasive phases

The use of multiple pole tips in a Magnetic Abrasive Finishing (MAF) system allows for shorter processing times, but it can also exacerbate any difficulties encountered in abrasive insertion and distribution. This paper proposes a hybrid tool that initially works as fixed abrasive but works as loose abrasive once the abrasive binder dissolves into the lubricant. The fixed-abrasive configuration simplifies the abrasive insertion, and the loose-abrasive configuration ensures the abrasive uniform distribution along the workpiece surface. The internal finishing of needles demonstrated that the hybrid tool saves about 80% abrasive insertion time while achieving a smooth surface equivalent to the conventional MAF method.

Improving the surface quality in wire electrical discharge machined specimens by removing the recast layer using magnetic abrasive finishing method

This study explores the feasibility of removing the recast layer formed on aluminum alloy cylindrical specimens machined by wire electrical discharge machining (WEDM) by using magnetic abrasive finishing (MAF). The WEDM is a thermal machining process capable of accurately machining parts with high hardness or complex shapes. The sparks produced during the WEDM process melt the metal’s surface. The molten material undergoes ultra-rapid quenching and forms a layer on the surface defined as recast layer. The recast layer may be full of craters and microcracks which reduce service life of materials tremendously, especially under fatigue loads in corrosive environments. This investigation demonstrates that MAF process, can improve the quality of WEDM machined surfaces effectively by removing the recast layer. The present work studies the effect of some parameters, i.e., linear speed, working gap, abrasive particle size, and finishing time on surface roughness and recast layer thickness using full factorial analysis. Three-level full factorial technique is used as design of experiments for studying the selected factors. In order to indicate the significant factors, the analysis of variance has been used. In addition, an equation based on regression analysis is presented to indicate the relationship between surface roughness and recast layer thickness of cylindrical specimens and finishing parameters. Experimental results show the influence of MAF process on recast layer removal and surface roughness improvement.

Polishing of the aluminum sheets with magnetic abrasive finishing method

Recent needs to superfinished surfaces have motivated researchers to study on modern methods of polishing. Magnetic-assisted finishing is one of those methods which can generate mirror-like finished surfaces. This paper investigates the effects of some parameters, i.e., rotational speed of the permanent magnetic pole, working gap between the permanent pole and the workpiece, number of cycles, and the weight of the abrasive particles on aluminum surface finishing. Three-level full factorial method was used as design of experiments technique to study the selected factors. A total of 54 designed tests were done on aluminum sheet using an innovative material removal mechanism. Analysis of variance was used to determine significant factors and also to obtain an equation based on data regression. Experimental results indicate that the number of cycles and working gap are the most significant parameters on surface roughness change (∆Ra), followed by rotational speed and then weight of powder.

TECHNOLOGICAL ANALYSIS OF FLAT SURFACE CONDITIONS BY MAGNETIC ABRASIVE FINISHING METHOD (MAF)

This study introduced the effect of using magnetic abrasive finishing method (MAF) for finishing flatsurfaces. The results of experiment allow considering the MAF method as a perspective for finishing flatsurfaces, forming optimum physical mechanical properties of surfaces layer, removing the defective layersand decreasing the height of micro irregularities. Study the characteristics which permit judgment parameters of surface quality after MAF method then comparative with grinding.

The Research of NC Magnetic Abrasive Finishing for Mould Parting Surface

In this paper, a new kind of NC magnetic abrasive finishing method with meshy polishing track to grind the parting face of mould was presented, and a new simple polishing tool using permanent magnet was also developed. Using the magnetic polishing tool, 3D NC polishing experiments was conducted on 2D parting surfaces. Experimental results reveal the relationship between several main parameters (rotational speed of magnetic pole, working gap, feeding speed and number of polishing times) and surface roughness. This study is expected to be helpful to improve the efficiency of finishing process, reduce worker's labor intensity, realize the effective control of finishing process and obtain fine quality of workpiece surface.

Effective Deburring of the Burr at Intersecting Hole by Permanent Magnet Inductor

The sharp burrs produced by plastic deformation during machining of the precision components deteriorates the precision and performance of a machine. Thus, effective removal of the burrs may improve productivity and performance of the machinery. This study was conducted based on the experiment to remove fine burrs produced during machining process using the magnetic abrasive finishing method. The magnetic abrasive finishing using the abrasive feature of an abrasive and the magnetic nature of iron is an abrasive method to brush the burrs with iron powder that has a cohesive power due to the line of induction. The purpose of this study is to remove the burrs at intersecting holes which are difficult to access with tools, using the magnetic abrasive finishing method. Special tool is designed for deburring micro burr at intersecting holes. To find the proper deburring condition, gap distance, rotational speed of inductor, components of powder and effect of coolant are analyzed.

Technique of Comparison and Optimization of Conditions for Magnetic Abrasive Finishing

In this paper, the new technique involving comparison and optimization of conditions for Magnetic Abrasive Finishing (MAF) is suggested, taking into account the basic laws stated for process MAF. The formulas for the calculation of the criteria for optimization are created when the process MAF is used for polishing, removal of burrs, and other purposes. The application of the technique is shown in an experiment on the optimization conditions for the removal of burrs after drilling using the MAF method. The technique can be used after standards for this process are developed.

Characterization of the Magnetic Abrasive Finishing Method and Its Application to Deburring

This paper analyzes the effectiveness of using Magnetic Abrasive Finishing (MAF) to remove burrs on drilled holes located on planes. Basic elements of the equipment in this method are a magnetic inductor; powder with magnetic and abrasive properties, which serves as the cutting tool; and the face electromagnetic inductor and the vibrating table, which were developed for deburring and finishing on flat surfaces. The performance of magnetic abrasive powders produced by industry is also evaluated. A new technique was developed to compare the performance of the magnetic abrasive powders and to find the powder that is appropriate for finishing and deburring drilled holes placed on a plane steel surface.

230 Development of Deburring Technology for Drilling Burrs using Magnetic Abrasive Finishing Method

The results obtained from the method of Magnetic Abrasive Finishing are presented in this paper, which verify the effectiveness of burr removal after drilling. The paper contains information about the development for research using electromagnetic inductor, tests of magnetic abrasive powders, and the effectiveness of deburring. The analysis of the results shows that this method is practical for burr removal in industry.