Research Papers

Investigations on the Application of Elastomagnetic Abrasive Balls for Fine Finishing

[+] Author and Article Information
V. S. Sooraj

Department of Aerospace Engineering,
Indian Institute of Space Science and
Technology (IIST),
Thiruvananthapuram, Kerala 695547, India
e-mail: sooraj.iist@gmail.com

V. Radhakrishnan

Department of Aerospace Engineering,
Indian Institute of Space Science and
Technology (IIST),
Thiruvananthapuram, Kerala 695547, India
e-mail: vprmfg@hotmail.com

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received August 26, 2014; final manuscript received December 9, 2014; published online February 4, 2015. Assoc. Editor: Radu Pavel.

J. Manuf. Sci. Eng 137(2), 021018 (Apr 01, 2015) (9 pages) Paper No: MANU-14-1447; doi: 10.1115/1.4029375 History: Received August 26, 2014; Revised December 09, 2014; Online February 04, 2015

This paper discusses a unique and flexible mode of applying fine abrasive grains in the form of mesoscale elastomagnetic abrasive balls, controlled using magnetic field, to achieve micro/nanoscale surface finish. The proposed balls are easy to load in the working gap to form an elastomagnetic abrasive brush that can be moved over the surface to get the required microcutting action. The effect of elastomeric medium present in the balls is clearly illustrated, and proven to be a viable approach for yielding ultra fine finish without altering the surface form. An analytical model is presented to describe the effect of finishing forces, torque, as well as the major process variables affecting the material removal. Detailed experimental investigation is reported with the statistical analysis of results and the validation of theoretical model.

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Fig. 1

Details of elastomagnetic abrasive brush

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Fig. 2

Elastomagnetic abrasive finishing setup

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Fig. 4

Action of an individual ball and the effect of elastomeric medium

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Fig. 5

The effect of brush rotation and feed rate of work specimen

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Fig. 6

Mechanism of micro/nanochips during finishing operation

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Fig. 7

Fishbone diagram showing major process variables

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Fig. 8

Effect of process variables and the response plots

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Fig. 9

The effect of processing time

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Fig. 10

Macroscopic image and profile of the surface

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Fig. 11

Comparison of theoretical and experimental values




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