Modeling of finishing force and torque in ultrasonic-assisted magnetic abrasive finishing process

Abstract

A new finishing technique called ultrasonic-assisted magnetic abrasive finishing integrates ultrasonic vibration with magnetic abrasive finishing process for finishing of workpiece surface more efficiently as compared to magnetic abrasive finishing in the nanometer range. During finishing, two types of forces are generated in ultrasonic-assisted magnetic abrasive finishing, namely, a normal force (indentation force) and a tangential force (cutting force) that produces a torque. The finishing forces have direct control on the rate of change of surface roughness and material removal rate of the workpiece surface. This article deals with the theoretical modeling of the normal force and the finishing torque based on the process physics. In this work, finite element simulations of the electromagnet were performed to calculate a magnetic flux density in the working zone; they were also used to evaluate the normal force on the workpiece surface. The theory of friction for the abrasion of metals was applied together with the effect of ultrasonic vibration to calculate the finishing torque. The developed model predicts the normal force and finishing torque in ultrasonic-assisted magnetic abrasive finishing as functions of the supply voltage, working gap and concentration of abrasive particles in a flexible magnetic abrasive brush. A comparison of theoretical and experimental results is performed to validate the proposed model.

Multi-objective optimization of ultrasonic-assisted magnetic abrasive finishing process

“…In the FMAB, only a few abrasive particles comes in contact with the workpiece surface and actually take part in the finishing action; they are termed as active abrasive particles. These particles experience a magnetic levitation force that enables them to create a microindentation onto the surface of the workpiece [15]. The rotation of electromagnet and the vibratory motion causes a relative motion between the active abrasive particles and the workpiece surface.…”

Effect of abrasive particle morphology along with other influencing parameters in magnetic abrasive finishing process

“…Misera et al [15,16] presented a mathematical model of finishing force and the surface roughness during UAMAF. Their model shows that the relationship between change in surface roughness and finishing time is exponential.…”

A magnetic shear thickening media in magnetic field–assisted surface finishing

“…Magnetic field-assisted finishing techniques have elicited considerable research interest, [1][2][3] in which a flexible brush formed by magnetic field domination is employed to navigate against and across workpiece surfaces. Flexibility, self-sharpening, and self-adaptive are typical characteristics of the magnetic abrasive brush.…”