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Research Papers

Experimental Investigations and Modeling of Finishing Force and Torque in Ultrasonic Assisted Magnetic Abrasive Finishing

[+] Author and Article Information
Rahul S. Mulik

Department of Mechanical Engineering, Indian Institute of Technology Delhi, New Delhi-110 016, India

Pulak M. Pandey1

Department of Mechanical Engineering, Indian Institute of Technology Delhi, New Delhi-110 016, Indiapmpandey@mech.iitd.ac.in

1

Corresponding author.

J. Manuf. Sci. Eng 134(5), 051008 (Sep 10, 2012) (12 pages) doi:10.1115/1.4007131 History: Received July 07, 2011; Revised July 11, 2012; Published September 10, 2012; Online September 10, 2012

An ultrasonic assisted magnetic abrasive finishing (UAMAF) process uses an ultrasonic vibrations and magnetic abrasive finishing (MAF) process. In a finishing process there are two types of forces that act during the finishing of the workpiece by UAMAF, namely, normal force and cutting force. The finishing forces have direct influence on the generation of the finished surface and accuracy of the workpiece. Therefore, in the present work, normal force and finishing torque have been measured at various processing conditions during UAMAF. Supply voltage to the electromagnet and finishing gap have been found to be the significant factors affecting the finishing forces and torque. Mathematical models based on process physics have been developed to predict the finishing force and torque. The developed models predict force and torque as a function of supply voltage, machining gap, and workpiece hardness. The developed mathematical models for normal force and finishing torque have been validated and were found to be in good agreement with experimental results.

Copyright © 2012 by American Society of Mechanical Engineers
Topics: Force , Torque , Finishing , Modeling
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References

Figures

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Figure 2

Schematic of forces acting during UAMAF: (a) Details of electromagnet with forces and (b) details of forces on a single abrasive

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Figure 3

Experimental setup to measure normal forces and finishing torque during UAMAF: (a) Schematic diagram and (b) actual photograph

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Figure 4

The schematic of an electromagnet and flux distribution: (a) Arrangement of poles in electromagnet and (b) change in flux density along axial direction from the center of the electromagnet toward the outer periphery of the electromagnet at different input voltages to the electromagnet

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Figure 5

Variation of normal force and finishing torque with time, SiC abrasive mesh no. = 800, and Toff  = 2 s kept constant

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Figure 6

Variation of normal force and finishing torque with voltage and machining gap: (a) Normal force (Fn ) and (b) finishing torque. The rotation of magnet = 280 rpm, abrasive weight = 25%, and Ton  = 3 s are kept constant.

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Figure 7

Variation of normal force and finishing torque with machining gap and voltage: (a) Normal force (Fn ) and (b) finishing torque. Rotation of magnet = 280 rpm, abrasive weight = 25%, and Ton  = 3 s are kept constant.

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Figure 8

Schematic of abrasive brush formed below the poles of the electromagnet

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Figure 9

SEM micrograph of unbonded SiC abrasives (800 mesh)

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Figure 10

Schematic of an abrasive penetrating into the workpiece: (a) Depth of penetration, (b) projected area of indentation, and (c) projected area of penetration

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Figure 11

Calculation of Δt

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Figure 12

Schematic of magnetic and abrasive particles (MAPs): (a) Arrangement of MAPs and (b) forces acting on a single abrasive grit

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Figure 13

Flow chart to predict the normal force and finishing torque

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Figure 14

Comparison of experimental and predicted values of (a) normal force and (b) finishing torque during UAMAF for different voltage values

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Figure 15

Comparison of experimental and predicted values of (a) normal force and (b) finishing torque during UAMAF for different machining gaps

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Figure 1

SEM and AFM images showing the finishing mechanism during UAMAF: (a) SEM image of ground surface (Ra = 0.1024 μm); (b) SEM image after UAMAF (Ra = 0.0219 μm), at input voltage = 70 V, rotation of magnet = 280 rpm, mesh no. = 800, abrasive weight = 25%, Ton  = 3 s, and Toff  = 2 s; and (c) AFM image after UAMAF (Ra = 0.0219 μm)

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