Research Papers

Concept and Mechanics of Fine Finishing Circular Internal Surfaces Using Deployable Magneto-Elastic Abrasive Tool

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

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

1Corresponding author.

Manuscript received August 30, 2016; final manuscript received March 8, 2017; published online April 20, 2017. Assoc. Editor: Y. B. Guo.

J. Manuf. Sci. Eng 139(8), 081001 (Apr 20, 2017) (13 pages) Paper No: MANU-16-1472; doi: 10.1115/1.4036289 History: Received August 30, 2016; Revised March 08, 2017

Fine finishing of cylindrical internal surfaces without affecting geometric form is a critical requirement in several mechanical and aerospace applications. Although various methodologies using flexible abrasive media are reported for the same, many of them demand complex tooling and fixtures to be developed in tune with the internal dimensions to feed the abrasive media. The present paper investigates the feasibility of using magneto-elastic abrasive balls with the aid of a mechanically deployable tool for microfinishing of geometrically symmetric tubular specimens. The deployable tool used for the present experimentation is designed like an umbrella mechanism, with magnetic pads to hold the elastic abrasive balls, expandable for bore diameter ranges from 45 to 75 mm. The magnetic type elastic abrasive balls proposed in the form of mesoscale balls of diameter 3.5 ± 0.25 mm are capable of finishing the bore surface without altering its roundness. Effects of elastomeric medium, mechanics of material removal and generation of finished profile during the proposed technique have been discussed in detail, through a comprehensive mathematical model. Effect of various process variables on surface roughness was investigated experimentally using response surface methodology and the theoretical predictions were validated at optimum operating condition. Sixty-two percent reduction in average roughness on brass tubes of initial roughness 0.168 μm, with significant improvement in all the associated two-dimensional roughness parameters and without any deviation on roundness, was clearly demonstrating the potential of proposed methodology.

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Fig. 1

Schematic of mechanically deployable magneto-elastic abrasive tool

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Fig. 2

Details of finishing setup

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Fig. 3

Free body diagram of finishing forces

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Fig. 4

Macroscopic images of magneto-elastic abrasive balls: (a) standard abrasive gift and (b) magneto-elastic abrasive ball

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Fig. 5

Contact analysis of magneto-elastic abrasive ball versus standard abrasive grit

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Fig. 6

Mechanics of cutting and finishing

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Fig. 7

Pads used for contact experiments

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Fig. 8

Mechanics of chip removal by spherical abrasive grain

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Fig. 9

Mechanics of chip removal by nonspherical grains with positive rake angle: (a) with the rolling of elastic abrasive ball and (b) without the rolling of elastic abrasive ball

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Fig. 10

Configurations of grains in deformed contact zone

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Fig. 11

Distribution of embedded grain size and depth of penetration

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Fig. 12

Normal probability plot for grain size

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Fig. 13

Mechanics of finishing and behavior of balls in successive passes: (a) initial roughness profile and (b) profile after processing

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Fig. 14

Fishbone diagram of process variables

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Fig. 15

Effect of radial expansion on roughness

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Fig. 16

Effect of tool rotation on roughness

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Fig. 17

Effect of feed rate on roughness

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Fig. 18

Effect of abrasive grain size on roughness

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Fig. 19

Surface plot for optimum operating condition

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Fig. 20

Variation of roughness with processing time

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Fig. 21

Roughness profile before and after processing: (a) before processing and (b) after processing

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Fig. 22

Comparison of theoretical and experimental results




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