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Research Papers

Force Measurement and Analysis for Magnetic Field–Assisted Finishing

[+] Author and Article Information
Vasishta Ganguly

Research Assistant
e-mail: vganguly@uncc.edu

Tony Schmitz

Associate Professor
e-mail: tony.schmitz@uncc.edu
Department of Mechanical Engineering
and Engineering Science,
University of North Carolina at Charlotte,
Charlotte, NC 28262

Arthur Graziano

Research Assistant
e-mail: graziano@ufl.edu

Hitomi Yamaguchi

Associate Professor
e-mail: hitomiy@ufl.edu
Department of Mechanical and
Aerospace Engineering,
University of Florida, Gainesville, FL 32611

Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received August 24, 2012; final manuscript received February 7, 2013; published online July 17, 2013. Assoc. Editor: Y. B. Guo.

J. Manuf. Sci. Eng 135(4), 041016 (Jul 17, 2013) (9 pages) Paper No: MANU-12-1254; doi: 10.1115/1.4023723 History: Received August 24, 2012; Revised February 07, 2013

Magnetic field–assisted finishing (MAF) is used to polish free-form surfaces. The material removal mechanism can be described as a flexible “magnetic brush” that consists of ferromagnetic particles and abrasives that arrange themselves in the working gap between the magnet and the workpiece. Relative motion between the brush and the workpiece causes microcutting and improves surface finish. In this study, the contributions of the magnetic and polishing force components to the total force were evaluated. The effect of varying the polishing conditions, such as the working gap and the size of the ferromagnetic iron particles, on polishing forces, surface roughness, and material removal rate was also analyzed. It was observed that the polishing forces varied considerably with working gap. Also, the iron particle size was found to have a strong relation to the rate at which the surface roughness improved. Surface roughness values of 2–3 nm were achieved.

Copyright © 2013 by ASME
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References

Shinmura, T., Takazawa, K., Hatano, E., Matsunaga, M., and Matsuo, T., 1990, “Study on Magnetic Abrasive Finishing,” CIRP Ann., 39(1), pp. 325–328. [CrossRef]
Fox, M., Agrawal, K., Shinmura, T., and Komanduri, R., 1994, “Magnetic Abrasive Finishing of Rollers,” CIRP Ann., 43(1), pp. 181–184. [CrossRef]
Jain, V. K., Singh, D. K., and Raghuram, V., 2008, “Analysis of Performance of Pulsating Flexible Magnetic Abrasive Brush (P-FMAB),” Mach. Sci. Technol., 12(1), pp. 53–76. [CrossRef]
Yamaguchi, H., and Shinmura, T., 1999, “Study of the Surface Modification Resulting From an Internal Magnetic Abrasive Finishing Process,” Wear, 225–229, pp. 246–255. [CrossRef]
Jain, V. K., 2009, “Magnetic Field Assisted Abrasive Based Micro-/Nano-Finishing,” J. Mater. Process. Technol., 209(20), pp. 6022–6038. [CrossRef]
Jayswal, S. C., Jain, V. K., and Dixit, P. M., 2005, “Modeling and Simulation of Magnetic Abrasive Finishing Process,” Int. J. Adv. Manuf. Technol., 26(5–6), pp. 477–490. [CrossRef]
Mori, T., Hirota, K., and Kawashima, Y., 2003, “Clarification of Magnetic Abrasive Finishing Mechanism,” J. Mater. Process. Technol., 143–144, pp. 682–686. [CrossRef]
Singh, D. K., Jain, V. K., and Raghuram, V., 2009, “Parametric Study of Magnetic Abrasive Finishing Process,” J. Mater. Process. Technol., 149, pp. 22–29. [CrossRef]

Figures

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Fig. 1

MAF process (the normal, Fn, and lateral, Fx, force components are identified)

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Fig. 2

Schematic of experimental setup

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Fig. 3

Schematic of experimental setup for measuring magnetic flux density

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Fig. 4

Magnetic flux density for magnet only

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Fig. 5

Magnetic flux density with sample mount

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Fig. 6

Normal force measurement (PC1)

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Fig. 7

Normal force effects (PC1)

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Fig. 8

Normal force (approach) (PC1)

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Fig. 9

Normal force (retract) (PC1)

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Fig. 10

Velocity components of abrasive particle

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Fig. 11

Velocity vector plot for particles in the brush

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Fig. 12

Lateral force measurement (PC1)

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Fig. 13

Schematic of surface roughness measurement locations

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Fig. 14

Cross section of dimple (PC3)

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Fig. 15

Polishing force measurements for varying iron particle size (PC1–PC4)

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Fig. 16

Polishing force measurements for varying working gap size (PC5–PC8)

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Fig. 17

Effect of velocity on lateral force (PC3)

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Fig. 18

Surface roughness measurement for varying iron particle size (PC1–PC4)

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Fig. 19

Surface profile section with schematic of iron particles

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Fig. 20

Surface roughness measurements for varying working gap size (PC1–PC4)

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Fig. 21

Surface roughness measurements (Sa in nm) for a working gap of 4 mm (PC8)

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Fig. 22

MRR (μm/min) as a function of IPS (PC1–PC4)

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Fig. 23

Direction of lay after polishing (PC3)

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Fig. 24

Variation in surface topography after polishing (PC3)

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Fig. 25

Cross-sectional view of polished/unpolished interface (PC3)

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Fig. 26

Light intensity plot of polished area sections (different iron particle sizes) (PC1–PC4)

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Fig. 27

Comparison of CSI (top) and AFM (bottom) measurements (PC3)

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