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Special Section: Micromanufacturing

Development of Spherical Magnetic Abrasive Made by Plasma Spray

[+] Author and Article Information
Hitomi Yamaguchi1

Department of Mechanical and Aerospace Engineering, University of Florida, 226 MAE-B, P.O. Box 116300, Gainesville, FL 32611hitomiy@ufl.edu

Kotaro Hanada

Advanced Manufacturing Research Institute, National Institute of Advanced Industrial Science and Technology (AIST), 1-2-1 Namiki, Tsukuba, Ibaraki 305-8564, Japan

1

Corresponding author.

J. Manuf. Sci. Eng 130(3), 031107 (May 06, 2008) (9 pages) doi:10.1115/1.2917353 History: Received August 18, 2007; Revised February 15, 2008; Published May 06, 2008

Magnetic abrasive used for the internal finishing of capillary tubes, which prevents accumulation of contamination and erratic flow of the conveyed fluid, is a composite particle, consisting of iron and Al2O3 abrasive grains. The irregularity of the magnetic abrasive shape, due to the mechanical crushing process, causes nonuniform depth of cut of the abrasive and restricts the improvement of the finished surface quality. This has resulted in a narrow range of finishing performance. Moreover, the irregularity of the magnetic abrasive shape brings about difficulty in merely introducing it into capillary tubes. To break through these difficulties, this research proposes to develop a spherical iron-based magnetic abrasive, which carries Al2O3 grains on the surface, made by plasma spray. First, this paper examines the feasibility of the plasma spray to make the existing magnetic abrasive more spherical, and suggests the conditions needed to produce the spherical magnetic abrasive. Second, it studies the development of the new spherical magnetic abrasive made of separate particles: iron particles and Al2O3 abrasive grains, which carries the nonferrous abrasive on the outer surface alone. Their finishing performance, evaluated through the experiments using SUS304 stainless steel tubes, shows their applicability to magnetic abrasive finishing.

Copyright © 2008 by American Society of Mechanical Engineers
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References

Figures

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Figure 1

Schematic of plasma spray principle

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Figure 2

Photograph of experimental setup

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Figure 3

SEM micrographs of WA magnetic abrasives: (a) existing and ((b)–(f)) plasma sprayed

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Figure 4

Relationship between morphology breakdown and plasma spray conditions

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Figure 5

X-ray diffraction of WA magnetic abrasives

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Figure 6

SEM micrographs and energy dispersive X-ray spectroscopy of WA magnetic abrasives

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Figure 7

Photograph of finishing equipment

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Figure 8

Changes in surface roughness and material removal with finishing time

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Figure 9

SEM micrographs of unfinished surface and surface finished with existing and plasma sprayed magnetic abrasives

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Figure 10

SEM micrographs of composites

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Figure 11

Relationship between morphology breakdown and plasma spray conditions: (a) spherical particles, (b) partially spherical particles, (c) bonded particles, and (d) unmelted particles. (Note: Bonded particles were not observed.)

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Figure 12

SEM micrographs of plasma sprayed particles

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Figure 13

SEM micrographs of plasma sprayed magnetic abrasive consisting of alumina colloidal solution covered spherical iron particles and WA abrasive

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Figure 14

Relationship between magnetic force and particles

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Figure 15

Changes in surface roughness and material removal with finishing time

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Figure 16

Changes in surface roughness and material removal with finishing time

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