Modeling and simulation of surface roughness in magnetorheological fluid based honing process

Paswan, Sunil Kumar; Bedi, Talwinder Singh; Singh, Anant Kumar

doi:10.1016/j.wear.2016.11.025

Cited by 56 publications

(39 citation statements)

References 17 publications

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“…When the motion is given to the tool, MR polishing fluid moves over the surface of the workpiece; it causes abrasion wear resulting in material removal in the form of microchips. The results obtained from the magnetostatic simulation in the form of numerical value of the magnetic field at the finishing cylindrical surface as well as flat-bottomed surface and the trend of variation of the magnetic field in the working gap satisfy the requirement for finishing the surfaces in the present work which can be validated from the other MR finishing processes [22,23]. Figure 3a shows the dimensions of the tool for finishing the internal cylindrical surface of the blind hole.…”

Section: Experimental Set-up With Tool Design and Finishing Mechanismsupporting

confidence: 74%

Experimental analysis of magnetorheological finishing of blind hole surfaces using permanent magnet designed tools

Sirwal

Singh

Paswan

2020

J Braz. Soc. Mech. Sci. Eng.

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Permanent mould dies are used for various plastic injection moulding products. Most of the mould cavity is blind and henceforth difficult to finish. In this study, a novel magnetorheological fluid-based finishing process using permanent magnet tools has been developed for nano-finishing of cylindrical blind hole surfaces. Tools to finish the internal and flat-bottomed surfaces of the cylindrical blind hole are developed. The finishing performance of both tools is evaluated for finishing ferromagnetic material used in dies. The material of the die is P20 tool steel having 41 HRC hardness. Response surface methodology using a central composite design technique has been utilized for the plan of experiments and analysis of significant process parameters on the percentage change in surface roughness using newly developed tools. During finishing the internal cylindrical blind hole surface, the process parameters like rotational speed, reciprocation speed and abrasive mesh size are found to be significant. However, during flat-bottomed surface finishing of cylindrical blind hole workpiece, rotational speed, abrasive mesh size and abrasives volume percentage are found to process significant parameters. Experimentation at optimized parameters results in the final surface finish of 83 nm on internal cylindrical surface and 93 nm on the flat-bottomed surface of cylindrical blind hole workpiece.

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Section: Experimental Set-up With Tool Design and Finishing Mechanismsupporting

confidence: 74%

Experimental analysis of magnetorheological finishing of blind hole surfaces using permanent magnet designed tools

Sirwal

Singh

Paswan

2020

J Braz. Soc. Mech. Sci. Eng.

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“…A uniformly smooth mirror was obtained in which helical abrasive particle trajectories were formed by rotation and reciprocating motion. A novel MR polishing process based on magnetorheological abrasive honing (MRAH) was introduced to finish the internal surface of a ferromagnetic cylindrical workpiece [24,25]. The electromagnet was driven by a rotating shaft, resulting in rotational motion and reciprocating linear motion, which made the abrasive particles translate and rotate, respectively, passing through the workpiece surface as in the case of the honing process.…”

Section: Introductionmentioning

confidence: 99%

Annular Surface Micromachining of Titanium Tubes Using a Magnetorheological Polishing Technique

Song

Peng

et al. 2020

Micromachines

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In this study, a novel magnetorheological (MR) polishing device under a compound magnetic field is designed to achieve microlevel polishing of the titanium tubes. The polishing process is realized by combining the rotation motion of the tube and the reciprocating linear motion of the polishing head. Two types of excitation equipment for generating an appropriate compound magnetic field are outlined. A series of experiments are conducted to systematically investigate the effect of compound magnetic field strength, rotation speed, and type and concentration of abrasive particles on the polishing performance delivered by the designed device. The experiments were carried out through controlling variables. Before and after the experiment, the surface roughness in the polished area of the workpiece is measured, and the influence of the independent variable on the polishing effect is judged by a changing rule of surface roughness so as to obtain a better parameter about compound magnetic field strength, concentration of abrasive particles, etc. It is shown from experimental results that diamond abrasive particles are appropriate for fine finishing the internal surface of the titanium-alloy tube. It is also identified that the polishing performance is excellent at high magnetic field strength, fast rotation speed, and high abrasive-particle concentration.

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“…In other variant of MRF named MFAF process for concen-trating the magnetic lines at the center of workpiece magnetic fixture is developed. Two types of magnets: permanent and electromagnet were used by the researchers [53][54][55][56][57]. Heating of electromagnet coil reduces the viscosity of MR fluid which can be avoided by using permanent magnet in place of electromagnet.…”

Section: Variants In Mrfmentioning

confidence: 99%

A review on magnetically assisted abrasive finishing and their critical process parameters

Kumari

Chak

2018

Manufacturing Rev.

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Magnetically assisted abrasive finishing (MAAF) processes are the precision material removal processes that have been applied to a large variety of materials from brittle to ductile and from magnetic to non magnetic. The MAAF process relies on a unique “smart fluid”, known as Magnetorheological (MR) fluid. MR fluids are suspensions of micron sized magnetizable particles such as carbonyl iron, dispersed in a non-magnetic carrier medium like silicone oil, mineral oil or water. The MAAF processes overcome the limitation of abrasive flow machining by deterministically control the abrading forces by applying magnetic field around the workpiece. MAAF process is divided into two parts; one is magnetorheological finishing (MRF) and another is magnetorheological abrasive flow finishing (MRAFF). The MRAFF process gives better results as compared to results of MRF because it has additional reciprocating motion of MR fluid. In this article the attempt has been made to review various technical papers related to MRF and MRAFF. The experimental setups, process parameters, MR fluid, modeling & optimization and applications are discussed in this paper. This review article will be useful to academicians, researchers and practitioners as it comprises significant knowledge pertaining to MAAF.

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Modeling and simulation of surface roughness in magnetorheological fluid based honing process

Cited by 56 publications

References 17 publications

Experimental analysis of magnetorheological finishing of blind hole surfaces using permanent magnet designed tools

Experimental analysis of magnetorheological finishing of blind hole surfaces using permanent magnet designed tools

Annular Surface Micromachining of Titanium Tubes Using a Magnetorheological Polishing Technique

A review on magnetically assisted abrasive finishing and their critical process parameters

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