Magnetic Abrasive Machining Process Research Articles

Influence of process parameters on magnetic abrasive machining efficiency

The development of modern mechanical engineering forces us to constantly improve the technology of processing materials and look for ways not only to improve the quality of products but also to increase the efficiency of the processing process itself. This article discusses an alternative method to finish the product, which can replace the traditional method of grinding, magnetic abrasive treatment. This is a modern solution that allows you to obtain high surface quality of the processed product with minimal defects in their surface layer, and reduce the number of technological operations, which has a beneficial effect on the efficiency of the processing process. The efficiency of the magnetic abrasive machining process, which was determined by the amount of specific removal of the material, is influenced by many parameters, some of which were studied in this article: electromagnetic induction and processing time. The success of the application of magnetic abrasive treatment can also be judged by the topography of the surface of the product made using an electron microscope. The data obtained in the course of the study demonstrated the importance of individual input parameters of the magnetic abrasive treatment process in the formation of the surface layer of the product. According to the results of experimental studies, the dependences of the varied parameters were determined and recommendations were formed to improve the efficiency of the use of the magnetic abrasive process.

Experimental Examination on Finishing Characteristics of Aluminum Pipes in Magnetic Abrasive Machining Using SiC Contained Glued Magnetic Abrasives

With the rapid development in the industry, applications of finished parts are increasing day by day. However, the surface finish of the parts fabricated by conventional processes could not readily meet the requirements of various applications. Therefore, post-processing is needed to further improve the surface quality. Magnetic abrasive machining uses a flexible magnetic abrasive brush to remove material from the workpiece surface at a controllable rate. This cutting tool sticks to the workpiece during finishing operation and exerts a small force on the surface. In magnetic abrasive machining, the cutting tool neither requires compensation nor dressing. In this paper, the internal finishing of aluminum pipes has been investigated in magnetic abrasive machining tests using silicon carbide-based glued magnetic abrasives. For evaluating the performance of these magnetic abrasives, experimental work according to the central composite design technique was carried out to finish the aluminum pipes. The results so obtained were analyzed to study the influence of process parameters like magnetic field strength, speed of workpiece, abrasive mesh size and quantity of magnetic abrasives on percentage improvement in surface finish and material removal rate. The analysis showed that magnetic field strength was the most effective parameter while finishing the aluminum pipe followed by the quantity of magnetic abrasives. The finishing at optimal condition resulted in a surface finish of 0.07 μm. Further, scanning electron microscopy of the surface before and after magnetic abrasive machining was taken to study the improvement in surface finish.
 HIGHLIGHTS
 
 Magnetic abrasive machining (MAM) of aluminum work specimens have been performed by SiC-based magnetic abrasives
 The central composite design has been used for planning and execution of experiments
 The surface finish and material removal rate of the machined work specimens have been analysed as a performance measure of MAM process
 The high value of improvement in surface finish and material removal rate at optimum machining conditions have been observed
 Scanning electron microscopy (SEM) has been employed to study the surface topography of machined surfaces
 
 GRAPHICAL ABSTRACT

Investigation of a novel ultrasonically aided electrochemical magnetic abrasive machining process for SS 316L

Many present day applications require machining and finishing of complex-shaped and tough to machine materials with precision and accuracy by conventional or non-conventional machining and polishing processes. Ultrasonically aided electrochemical magnetic abrasive machining (UAEMAM) process is a novel non-conventional machining technique which can machine and finish the product for better surface quality. In present research work, the development and performance evaluation of UAEMAM process for machining of SS 316L is reported. The UAEMAM process is optimised using response surface methodology (RSM) based on central composite design (CCD) and grey relational analysis. The main machining variables of UAEMAM such as work piece rotational speed, working gap, concentration of NaNO3, percentage of abrasives by weight and pulse on time were considered to determine percentage improvement in surface finish (PISF) and material removal rate (MRR). The significant machining factors and the best combination levels of machining parameters associated with PISF and MRR were determined. The present work shows complete elimination of oxide layer from work piece surface, subsequently increasing the PISF value to 84.73 which is 2.73% higher than value achieved by previous studies employed. The benefits of ultrasonic aided electrochemical magnetic abrasive machining were also confirmed from the micrograph observations of the surface. Experimental results show that UAEMAM process is effective for machining and polishing components for better surface finish.

Effect of magnetic abrasive machining process parameters on internal surface finish

The surface finish is an important characteristic of the machined surface which is influenced by wear, friction and rotation of the mechanical component. In this work, the effect of different range of process parameters like working gap, rotational speed and machining time on magnetic-abrasive machining process are analyzed. The finishing action is done on mild steel cylindrical work piece. Moreover, the optimization of the best parameter at a particular range of electromagnetic flux for surface roughness of mild steel tube is done by Taguchi method. For surface roughness, the working gap is significant, followed by machining time and rotational speed, and obtained the optimum value of surface roughness (Ra) is 1.489 µm at 35 mm working gap, 430 rpm rotational speed and 2 min. machining time.

A Review on Parametric Analysis of Magnetic Abrasive Machining Process

The magnetic abrasive machining (MAM) process is a highly developed unconventional machining process. It is frequently used in manufacturing industries for nanometer range surface finishing of workpiece with the help of Magnetic abrasive particles (MAPs) and magnetic force applied in the machining zone. It is precise and faster than conventional methods and able to produce defect free finished components. This paper provides a comprehensive review on the recent advancement of MAM process carried out by different researcher till date. The effect of different input parameters such as rotational speed of electromagnet, voltage, magnetic flux density, abrasive particles size and working gap on the performances of Material Removal Rate (MRR) and surface roughness (Ra) have been discussed. On the basis of review, it is observed that the rotational speed of electromagnet, voltage and mesh size of abrasive particles have significant impact on MAM process.

Magnetic Abrasive Machining of Difficult-to-Cut Materials for Ultra-High-Speed Machining of AISI 304 Bars.

This research proposes an optimized magnetic abrasive machining process that uses an ultra-high-speed system to perform precision machining on a workpiece. The system can process several microns of material, either for machining surface roughness or for machining a workpiece for a precise micro-diameter. The stainless steel workpieces have been machined using an ultra-high-speed magnetic abrasive machining (UHSMAM) process. The experiments were performed analyzing the accuracy of the machined workpiece diameter, using response surface methodology. The results obtained after machining have been analyzed to determine the effect of different process parameters such as machining speed, machining time, machining frequencies, inert gas in/out, magnetic pole types, and magnetic abrasive mesh size for the individual workpiece, as well as to study various interaction effects that may significantly affect the machining performance of the process. The obtained outcomes of the analysis for different workpieces have been critically compared to understand the effect of the considered process parameters based on the resulting mechanical properties. Regression analysis was used to confirm the stability of the micro-diameter and the processing efficiency. Atomic force microscope (AFM) micrographs were also obtained to study the surface morphology of the precision-machined workpiece.

Characteristics of ultra-high-speed micro processing machines using magnetic abrasive machining methods

Magnetic abrasive machining (MAM) is a machining technique in which magnetic fields are used to control abrasive tools during the machining process of a material. Due to the development of engineering technologies, various properties such as surface accuracy, dimensional accuracy, and lightweight materials are required in current engineering applications. This study proposes the development of a new ultra-high-speed magnetic abrasive machining technique with the goal of improving the dimensional accuracy, surface accuracy and weight of a material. Moreover, to reduce machining time, this machining method was developed using an ultra-high-speed spindle, capable of rotating up to 80000 rpm. In this study, Ti-6Al-4V (Eli) bars were used as cylindrical workpieces and were machined via magnetic abrasive machining processes with an ultra-high-speed spindle. Results showed that improvements in the diameter and quantity of removed material were the highest at an operational speed of 80000 rpm, followed by 40000 rpm, 20000 rpm and 2000 rpm. The initial surface roughness of 0.21 μm Ra was improved to 0.04 μm Ra at 80000 rpm for 75 seconds. To evaluate the machining capabilities of the ultra-high-speed MAM process in terms of surface roughness, a descriptive statistical method was used. Precision weight data, laser scan micrometer data, roundness data, surface roughness data, and AFM images of the machined surface were recorded and studied.

Modeling of the Magnetic Abrasive Machining Process of Flat Surface Workpieces on Numerically Controlled Machine Tools

The article describes a mathematical model of the circular motion trajectory of a magnetic abrasive powder portion which participates in the magnetic abrasive machining process of flat surface workpieces. The motion trajectory of a magnetic abrasive powder portion is observed. The main formulas, assumptions and recommendations on the implementation of the mathematical model are introduced. Taking into account the feed rate of the machine table, rotational speed and the radius of the cylindrical magnetic inductor, the model allows determining an optimal amount of the magnetic abrasive powder portion which can provide the required efficiency of the finishing process. The magnetic abrasive machining process does not have any fixed standard cutting parameters, so they have to be readjusted every time. The given model can be used to predict the parameters of the finishing process of sophisticated flat surface workpieces.

Modeling and Simulation of Cylindrical Electrochemical Magnetic Abrasive Machining Process

Cylindrical Electrochemical Magnetic Abrasive Machining (C-EMAM) is an advanced abrasion-based hybrid machining process that constitutes magnetic abrasive machining and electrochemical dissolution. During the C-EMAM process, a large amount of material is removed from the peaks of the surface irregularities under the simultaneous effect of electrochemical dissolution, abrasion and abrasion-passivation synergism. This article presents the mathematical modeling for material removal and surface roughness during the C-EMAM process. Magnetic potential distribution between the two magnetic poles in which a cylindrical workpiece was placed was calculated using the finite element method. It was further used to find the forces acting on the ferromagnetic particles at contact surfaces. An empirical relation has been also developed considering the effect of electrochemical dissolution and abrasion-passivation synergism based on experiments conducted on a self-developed C-EMAM setup. Finally, a surface roughness model was developed by considering the total volume of material removed with the assumption of a triangular surface profile. The simulated results for material removal and surface roughness were validated using self-conducted experimental results. The computed results were found to be in good agreement with experimental observations.

A study of electrochemical magnetic abrasive machining process

This paper presents the study of hybrid machining process consisting of electrochemical dissolution and magnetic abrasive machining. Experiments were conducted on self-developed cylindrical electrochemical magnetic abrasive machining (C-EMAM) setup to explore the finishing results of the process on non-magnetic stainless steel using unbonded magnetic abrasives. The effect of electrolytic current, magnetic flux density and rotational speed of workpiece on material removal and surface roughness were investigated. It was observed that the rotational speed of the workpiece, magnetic flux density and electrolytic current should be properly fitted to achieve passivation-abrasion synergism. The problems associated with the process, which reduces the performance are also discussed.

Electrochemical magnetic abrasive machining of AISI304 stainless steel tubes

This work presents the characteristics of advanced abrasion based hybrid machining process consisting of electrochemical dissolution and magnetic abrasive machining process. The cylindrical electrochemical magnetic abrasive machining (C-EMAM) setup was developed and mounted as an attachment on lathe for high efficiency machining of cylindrical jobs. Experiments were conducted to explore the performance of the process on AISI-304 stainless steel tubes using unbonded magnetic abrasives. The effect of various process parameters viz. rotational speed of the workpiece, current to the electromagnet, electrolytic current and frequency of vibration on material removal and surface roughness were investigated. The electrochemical process has major contribution in material removal, whereas magnetic abrasive machining helps in reduction in surface roughness. This process has higher machining efficiency particularly at high value of electrolytic current and high rotational speed.

Study on a Magnetic Deburring Method by the Application of the Plane Magnetic Abrasive Machining Process

This research studies the influence of constant pressure acting on the magnetic particles brush for the precision machining of planar and curved workpieces. In particular, it examined the effects of constant pressure on improving the formal accuracy of the workpiece. This process method, constant pressure is applied to the magnetic pole of a conventional magnetic brush, the constant pressure acted to the surface of the workpiece through the magnetic particle brush formed at the magnetic pole surface. The authors conducted a plane magnetic abrasive finishing experiment using both the conventional magnetic abrasive finishing process and the newly proposed constant-pressure magnetic abrasive finishing process to compare the deburring characteristics between the processes for removing burrs from holes drilled in brass plate workpieces. In this experiment, a brass disk with a drilled hole was used as a workpiece. As a result, the difference in finishing characteristics was clarified. The results showed that the burr can be removed by use of this new plane magnetic abrasive finishing process and it is more useful than the conventional magnetic brush for improving the shape accuracy of the workpiece.