Experimental study on reciprocating magnetorheological polishing

et al. 2023

ILT

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Purpose This paper aims to study the influence of the different parameters of magnetorheological polishing fluids (MRP fluids) on the surface roughness and material removal rate (MRR) of the workpiece surface in the reciprocating magnetorheological polishing (RMRP) process. Design/methodology/approach A series of single-factor experiments are performed to evaluate the influence of the concentration of magnetic particles, concentration of abrasive particles and size of abrasive particles on surface processing effects by using the RMRP method. Moreover, the yield stress and viscosity of MRP fluids are studied based on the Bingham plastic model by varying the MRP fluids parameters. Findings A reasonable parameter of MRP fluids is crucial to the surface roughness and MRR of the workpiece surface, and the optimized parameters are obtained by the single-factor experiments of RMRP. The results are when the concentration of carbonyl iron particles is 40 Vol.%, the concentration of CeO2 is 5 Vol.% and the size of CeO2 is 2.5 µm in the MRP fluids, the surface roughness of the workpiece remarkably decreases to 28 nm from the initial 332 nm and the MRR of the workpiece increases to 0.118 mg/min. Originality/value In this study, the single-factor experiments for the different parameters of MRP fluids are studied to polish K9 glass by using the RMRP device, and the yield stress and viscosity of MRP fluids are investigated by rheological experiments, which provides reference for a reasonable selection of the MRP fluids parameter in RMRP process.

Section: Experimental Conditionsmentioning

confidence: 99%

Research on influence of polishing fluids parameters on processing effects in reciprocating magnetorheological polishing

Wang¹,

et al. 2023

ILT

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“…Based on magnetohydrodynamic theory, the magnetic particles in the MRP fluids are attracted to the high magnetic region by external magnetic effect, and the nonmagnetic abrasive particles are pushed to the low magnetic region by magnetic fluids buoyancy effect, contacting with the workpiece surface. Thus, the obvious shear yield stress is produced in the system, and the ultraprecision machining of deterministic polishing is completed (Khan and Jha, 2018; Wang et al , 2022b; Kordonski and Gorodkin, 2011). Therefore, MRP is considered to be one of the most promising intelligent polishing methods in the future.…”

Section: Introductionmentioning

confidence: 99%

Analysis on machining uniformity in reciprocating magnetorheological polishing based on abrasive particle trajectory

Wang¹,

et al. 2023

ILT

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Purpose This paper aims to study the effects of the processing parameters in the reciprocating magnetorheological polishing (RMRP) on abrasive particle trajectory by the simulation analysis, which provides a basis for the machining uniformity of the workpiece. Design/methodology/approach The principle of the RMRP method is discussed, and a series of simulation analysis of the abrasive particle trajectory are performed to evaluate the effects of the workpiece’s rotational speed, the eccentric wheel’s rotational speed, the eccentricity and the frame gap on abrasive particle trajectory by using the RMRP method. Findings The processing parameters have a significant influence on the abrasive particle trajectory, and then the machining uniformity of the workpiece is affected. Under certain experimental conditions, the height difference of workpiece measuring points varies between 4 and 11 µm, and the height difference of equal radial measuring points is less than 1.5 µm by optimizing processing parameters. Originality/value In this study, the optimal processing parameters can be obtained by the simulation analysis of abrasive particle trajectory, which can replace the experimental methods to obtain the reasonable processing parameters for the machining uniformity of the workpiece. It provides references for the selection of processing parameter values in magnetorheological polishing process.

“…As stated above, a reciprocating magnetorheological polishing (RMRP) method was proposed, which used the reciprocating movement of the magnetic field to form a dynamic polishing brush, removing materials from the workpiece surface (Wang et al , 2022). The principle of the RMRP method combined the two movements of polishing brush translation and workpiece rotation to polish the workpiece, as given in Figure 1(a) and 1(b).…”

Section: Introductionmentioning

confidence: 99%

Study of machining parameters in reciprocating magnetorheological polishing process based on response surface methodology

Wang¹,

et al. 2022

ILT

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Purpose This paper aims to analyze the significance of machining parameters (workpiece’s rotational speed, magnet coil current and working gap) on final Ra (surface roughness) and material removal rate (MRR) of workpiece in reciprocating magnetorheological polishing (RMRP) process. Design/methodology/approach The research is planned to analyze, model and predict the optimum machining parameters to anticipate final Ra and MRR by applying response surface methodology (RSM) and multiresponse optimization (desirability function approach). The experiments have been planned by design of experiments (DOE). Analysis of variance (ANOVA) is applied to determine the significances of machining parameters on RMRP performance characteristics. Findings Response surface plots for final Ra and MRR by RSM show that machining parameters are significant for the responses. The optimum machining parameters obtained are optimized by desirability function approach (DFA), and the optimum parametric combination has been validated by confirmatory experiments. The experimental results of the final Ra and MRR are deviated by 5.12% and 2.31% from the response results under the same optimization conditions, respectively. Originality/value In this study, the RMRP responses (final Ra and MRR) are improved at predicted input machining parameters condition obtained by RSM and DFA approach. Furthermore, the research results provide a reference for experimental design and optimization of MRP process.