Optimization of process parameters affecting surface roughness in magnetic abrasive finishing process

Ahmad, Shadab; Gangwar, Swati; Yadav, Prabhat Chand; Singh, Devendra Pratap

doi:10.1080/10426914.2017.1279307

Cited by 47 publications

(17 citation statements)

References 24 publications

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“…It was concluded that R a , and surface morphology of the component depend on the type and abrasive size. Similar kind of investigations were reported by Kajal et al and Ahmad et al 26,27 From the literature, it is observed that very few authors have investigated the surface finish capabilities of both magnetic and nonmagnetic materials and the influence of process variables on surface finish improvement. Therefore, the present work discusses in detail about the surface characteristics of MS and Al 2024 while MAF processing.…”

Section: Introductionsupporting

confidence: 73%

Surface texture improvement of magnetic and non magnetic materials using magnetic abrasive finishing process

Anjaneyulu

Venkatesh

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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The present study focused on surface texture characteristics of magnetic material, Mild steel (MS) as well as nonmagnetic material, Aluminum 2024 (Al 2024) alloy with the application of a laboratory-developed magnetic abrasive finishing (MAF) process. MAF is one of the unconventional finishing processes to attain a satisfactory finishing level up to nanoscale. In MAF, the surface finish is controlled by a flexible magnetic abrasive brush (FMAB) which has a combination of abrasives (Al2O3, SiC, etc.) and magnetic particles (iron powder). The experiments were planned using (L27) full factorial design, different levels of weight percentage of abrasives (20–30%), speed of the electromagnet (180–2100rpm), and electromagnet supply voltage (30–50 V) were varied to enhance the surface responses. The responses considered were % improvements of change in the surface finish (%ΔRa), change in average peak to valley height (%ΔRz), change in total profile height (%ΔRt), and change in mean square root surface finish (%ΔRq). Analysis of variances (ANOVA) was evaluated and discussed. It is observed that the speed of the electromagnet and voltage are the most influencing variable parameters that most impacted on the responses. Surface roughness was measured before and after the MAF processing of MS and Al 2024 using a Suftronic S-100 surface roughness tester. The obtained surface morphology was examined by Scanning Electron Microscopy (SEM). It was observed that MS has %ΔRa = 83, %ΔRz = 65, %ΔRt = 65.5 and %ΔRq = 72.6 while Al 2024 has %ΔRa = 65, %ΔRz =50, %ΔRt = 51 and %ΔRq = 55 with noticeable surface texture improvement compared to the initial surface roughness obtained using surface grinding process.

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Section: Introductionsupporting

confidence: 73%

Surface texture improvement of magnetic and non magnetic materials using magnetic abrasive finishing process

Anjaneyulu

Venkatesh

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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“…So bound magnetic abrasive particles (sintering) are used for the abrasive process. The sintered magnetic abrasive technique is employed to prepare abrasive particles based on [18] by mixing iron powder (45 µm size, 60% by weight) and alumina powder (5 µm Fig. 3 The schematic of magnetic force applied on magnetic abrasive particles (coil no.…”

Section: Magnetic Abrasive Particlesmentioning

confidence: 99%

Development the flexible magnetic abrasive finishing process by transmitting the magnetic fields

Moghanizadeh

Ashrafizadeh

Bazmara

2021

Int J Adv Manuf Technol

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This research aims to present a novel approach in magnetic abrasive finishing to improve its potential for creating different finishing patterns in the free-form surface using no special fixtures or tool machines to minimize the complexity of the process. The key point of this idea is that magnetic abrasive particles can move in special patterns by transfer magnetic fields (similar to a magnetic train moving on a magnetic rail) and create the desired polishing patterns on the surface simultaneously. The coils are placed under a thin plate; then, a flexible magnetic path is created by a special arrangement of magnetic coils; after that, the coils are turned on and off in turn, and the magnetic abrasive particles move in the created path and abrasive the surface. The continuous movement of magnetic abrasive particles under the magnetic field will abrade the thin sheets' surface. The tests were performed on copper sheets with a thickness of 1 mm. Experimental parameters include electric current (0.25, 0.5, and 0.75 A), speed of turning on and off of the coils (speed of magnetic abrasive particle movement) (20, 30, and 40 mm/s), and process time (1, 2, and 3 h). The experiments were performed on L-shaped and free-form sheets. The results show that using a transmission magnetic field in the MAF (TMAF) makes it easy to create different surface roughness patterns in different directions simultaneously. While in one part of the L-shape the electric current is 0.25 A, the surface roughness is around 0.90 µm, in the other part, where the electric current is 0.75 A, the surface roughness is around 0.49 µm. Meanwhile, TMAF makes it possible to finish a free-form surface with no special fixtures. Moreover, there is a direct relationship between the change in the surface roughness and the electric current and process time.

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“…The magnetic flux assembles the MAPs in the form of MAB and its stiffness depends on the magnetic flux intensity in the machining gap. Super-finishing is accomplished by relative motion between the processed surface and MAB (Ahmad et al, 2017;Singh et al, 2004). This MAB acts as multi-point cutting head that remove the material in the form of micro-chips from the processed surface (Yamaguchi et al, 2012).…”

Section: Introductionmentioning

confidence: 99%

Multi-objective optimization of magnetic abrasive finishing by desirability function with genetic algorithm

Singh¹,

Gangwar²,

Singh³

et al. 2021

Int. J. Eng. Sci. Tech

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Thermal stability and Surface hardness of the super-finished surface is a very important aspect to preserve the surface texture of workpiece in the MAF process. In this present study, the multi-objective optimization of EN-31 finished through the MAF process. “Increase in Temperature” and “Increase in Hardness” are considered for optimization to diminish their impact on the super-finished surface of EN-31. In present work Desirability function analysis (DFA) has been used to optimize the desired responses of the MAF process. Experiments were designed according to Taguchi L9 orthogonal array for the finishing of EN-31. The experiment results are processed using DFA and Desirability fitness function is established to convert the single response to multi-response. Genetic Algorithm (GA) is used to enhance the results of DFA and the regression model was developed to obtain the objective function of Genetic algorithm. Smaller-the-best criteria were used for ‘Increase in Temperature’ and ‘Increase in Hardness’ for obtaining favorable process parameters. The best optimal parametric combination is obtained by using the GA-DFA hybrid approach is at 2.5 mm (working gap), 20 gm (abrasive weight), and 2.0 A (Current) and 300 rpm (rotational speed).

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Optimization of process parameters affecting surface roughness in magnetic abrasive finishing process

Cited by 47 publications

References 24 publications

Surface texture improvement of magnetic and non magnetic materials using magnetic abrasive finishing process

Surface texture improvement of magnetic and non magnetic materials using magnetic abrasive finishing process

Development the flexible magnetic abrasive finishing process by transmitting the magnetic fields

Multi-objective optimization of magnetic abrasive finishing by desirability function with genetic algorithm

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