Experimental and theoretical investigation into surface roughness and residual stress in magnetorheological finishing of OFHC copper

Ghosh, Gourhari; Sidpara, Ajay; Bandyopadhyay, P.P.

doi:10.1016/j.jmatprotec.2020.116899

Cited by 49 publications

(19 citation statements)

References 47 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Sim (2010) described that every year millions of Euros are spent trying to improve the quality of parts or components specially in aerospace industries by removing or avoiding such distortions. Ghosh (2021) mentioned in the article that even sometimes while polishing of workpiece, some amount of residual stresses is induced on workpiece surfaces leading to alteration in inter-planar spacing which directly influences the reflectivity and refraction index of polished product to be used in optical applications. Tyagi (2002) investigated the effect of residual stress on the optical properties of cadmium iodide films.…”

Section: Introductionmentioning

confidence: 99%

Experimental and theoretical investigation into surface roughness and residual stress using ball end magnetorheological finishing

Sharma

Niranjan

2022

JER is an international, peer-reviewed journal that publishes f

View full text Add to dashboard Cite

The generation of residual stresses by grinding process on the surface for a soft material results in poor performance and diminished life. In this paper, grinding-induced residual stresses is addressed and an attempt is made to relieve these residual stresses while achieving nano level surface finish using ball end magnetorheological finishing (BEMRF) process. BEMRF is a recently developed process that is effectively used to for fine figuring and polishing of a variety of magnetic and non-magnetic materials. In our present work we will demonstrate the relieving of residual stresses and reduction in surface roughness generated after surface grinding of Aluminium 7075 workpiece using BEMRF process. The impact of various BEMRF variables on reduction in surface roughness and residual stresses are discussed statistically and graphically. Residual stresses of workpiece surfaces have been measured by using portable X-ray residual stress analyzer. Significant process parameters affecting the residual stresses during polishing of workpiece are obtained using Analysis of variance (ANOVA) and F-test. It has been observed that reduction in residual stress is achieved along with nano level surface finish on aluminium workpiece surface using BEMRF technique.

show abstract

Section: Introductionmentioning

confidence: 99%

Experimental and theoretical investigation into surface roughness and residual stress using ball end magnetorheological finishing

Sharma

Niranjan

2022

JER is an international, peer-reviewed journal that publishes f

View full text Add to dashboard Cite

show abstract

“…The research shows the configuration of MRF liquids is complex because there are many parameters should be considered such as abrasive diameters, the magnetic field intensity, the magnetic flux directions and the magnetic pole shape. Ghosh et al [9] invested the surface roughness and residual stress in MRF, the wheel based magnetorheological finishing (MRF) process is used to attain nano-level surface roughness of oxygen-free high conductivity (OFHC) copper. As polishing tools do not contact to the workpiece in MRF, the wear of the polishing tools and temperature of the polishing area is stable, which improve the polishing accuracy.…”

Section: Introductionmentioning

confidence: 99%

Constrained abrasive jet polishing with a tangentially aligned nozzle shroud

Yuan

Chen

Wen

2022

Int J Adv Manuf Technol

View full text Add to dashboard Cite

In order to improve surface polishing quality and efficiency for hard and brittle components, a novel nozzle with specifically designed shroud was proposed for an abrasive jet polishing process. The removal mechanism of the abrasive jet under such a nozzle was investigated by simulating the jet flow in the interaction area of the nozzle shroud and workpiece. The simulation results show that the speed of the abrasive jet increases greatly by the shroud and the direction of the jet is aligned near parallel to the workpiece surface to minimize impact damage to workpiece surface. The constrained abrasive jet polishing (CAJP) experiments were conducted on the quartz glass component, a typical hard and brittle material, showing that the material removal mainly relied on the shearing and scratching of the workpiece surface rather than the mechanical shock impacts, which is consistent with the simulation findings.

show abstract

“…Alam Z et al [10] proposed the microscopic particle arrangement structure of magnetorheological polishing fluid, analyzed the stress model acted on abrasive particles by the above structure and the wear mechanism between abrasive particles and workpiece surface, and then established an effective surface roughness prediction model. Ghosh G et al [11] established a theoretical prediction model of machined surface roughness for the wheel-based magnetorheological polishing process of Oxygen Free High Conductivity (OFHC) copper, effectively optimizing the process parameters such as polishing wheel speed, machining clearance and feed speed, and finally obtained the ultra-precision machined surface with minimum Sa of 15.5 nm and residual compressive stress of 6.9 MPa. Wang Y et al [12] conducted a quantitative analysis of processed surfaces based on mathematical statistics on directional and non-directional texture models, and demonstrated that Dual-Rotation Magnetorheological Finishing (DRMRF) can suppress directional texture and effectively improve surface roughness.…”

Section: Introductionmentioning

confidence: 99%

Research on prediction method of surface roughness in weak magnetorheological shear thickening fluid polishing

Yang

Huang

Cai

et al. 2022

Int J Adv Manuf Technol

View full text Add to dashboard Cite

A joint prediction method of "mathematical modeling and finite element calculation" is proposed to improve the prediction of machining quality in weak magnetorheological shear thickening fluid polishing of complex surfaces. The study proceeded in several steps. First, based on both impact energy model and material removal model, a numerical prediction model of surface roughness is established. Second, based on the multi-peak fitting method, the field induced rheological properties of the polishing fluid are characterized and material properties of the flow field medium in the polishing zone are defined. Third, the numerical boundaries of polishing flow velocity and shear stress in the above prediction model are obtained. Fourth, the polishing experiments with parameters consistent with the above simulation model are conducted, and the initial surface roughness values are substituted into the above prediction model. The results show that the joint prediction method can effectively predict the machining quality of workpiece surface. The absolute error of Sa value of surface roughness is up to10.6 nm, and the maximum relative error is 12.3%. Keywords：Weak magnetorheological shear thickening fluid polishing, joint prediction method, surface roughness, field induced rheological properties

show abstract

Experimental and theoretical investigation into surface roughness and residual stress in magnetorheological finishing of OFHC copper

Cited by 49 publications

References 47 publications

Experimental and theoretical investigation into surface roughness and residual stress using ball end magnetorheological finishing

Experimental and theoretical investigation into surface roughness and residual stress using ball end magnetorheological finishing

Constrained abrasive jet polishing with a tangentially aligned nozzle shroud

Research on prediction method of surface roughness in weak magnetorheological shear thickening fluid polishing

Contact Info

Product

Resources

About