Experimental investigations on finishing of a brass specimen by magneto-rheological honing technique

2021 ◽  
pp. 251659842110157
Author(s):  
Chinu Kumari ◽  
Sanjay Kumar Chak
Keyword(s):  
Magnetic Field ◽  
Process Parameters ◽  
Surface Finish ◽  
Rotational Speed ◽  
Field Application ◽  
Surface Finishing ◽  
Experimental Investigations ◽  
Significant Parameter ◽  
Magnetizing Current ◽  
Magneto Rheological

Magneto-rheological abrasive honing (MRAH) is an unconventional surface finishing technique that relies on abrasives mixed with a unique finishing fluid, which changes its characteristics on magnetic field application. This process imparts nanometric-level surface finish with a significant amount of uniformity. Rotating motion of the workpiece and continuous reciprocation of the finishing fluid in the MRAH process are recognized as the major aspects for adopting this process in finishing non-magnetic materials. The finishing obtained through the MRAH process relies on the workpiece’s material properties and process parameters such as concentration of abrasives in finishing fluid, rotational speed of the workpiece, and magnetic field strength/magnetizing current. To study the efficacy of MRAH process, a parametric study was conducted by performing few experiments on a brass workpiece. Design of experiment approach was adopted to plan the experiments, and the effect of different values of magnetizing current, the concentration of abrasives, and rotational speed on the surface finish were analyzed through the application of analysis of variance (ANOVA). From ANOVA, the rotational speed was found as the most significant parameter with a contribution of 48.90% on % reduction in roughness value (%∇Ra). Around 57% of roughness reduction was obtained at the optimized value of process parameters.

Design and Development of Magnetorheological Fluid Machine for Flat Surface Finish

2020 ◽  
Vol 1013 ◽  
pp. 27-32
Author(s):  
Odwa Myataza ◽  
Khaled Abou-El-Hossein
Keyword(s):  
Magnetic Field ◽  
Surface Finish ◽  
Flat Surface ◽  
Low Cost ◽  
Magnetorheological Fluid ◽  
Surface Finishing ◽  
Design And Development ◽  
Mr Fluid ◽  
Motion System ◽  
Cnc Router

Surface finishing of glass and ceramics flats is difficult to perform using already existing traditional processes because of the brittle nature of these materials. In order to make traditional processes be able to accommodate these materials, relatively expensive aiding devices and approaches are required. The newly developed magnetorheological (MR) fluid finishing offers a solution to this problem at a relatively low cost. Magnetorheological fluids have been used in mechanical engineering applications because of the rheological behavior they possess under a magnetic field which enables the manipulation and pressure of loose abrasives on the machined surfaces and perform cutting action. This paper describes the design and development of an MR fluid machine-tool for flat surface finishing. The design presented herewith includes the design of the mechanical aspects of the ball-end tool machine and its support structure for a three-axis motion system. The objective of this study is realized based on utilizing a magnetic field, magnetorheological fluid and CNC router design to perform flat surface finishing.

A New Magnetic Polishing Liquid (MPL) for Precision Surface Finishing

2006 ◽  
Vol 315-316 ◽  
pp. 671-675 ◽  
Author(s):  
J. Jiang ◽  
Yong Bo Wu ◽  
Xu Yue Wang ◽  
M. Kato
Keyword(s):  
Magnetic Field ◽  
Surface Roughness ◽  
Magnetic Fields ◽  
Experimental Result ◽  
Surface Finishing ◽  
Hydrodynamic Characteristics ◽  
Magnetic Clusters ◽  
Abrasive Particles ◽  
Magneto Rheological ◽  
The Magnetic Field

This paper presents a new magnetic polishing liquid (MPL) produced by mixing sub-micron or micron order abrasive particles into a magnetic compound fluid (MCF) and its fundamental performance in surface finishing. MCF is an intelligent fluid, which is developed by mixing a magnetic fluid (MF) and a Magneto-rheological fluid (MRF) into a solvent, and hence reacting upon magnetic fields. In the present work, seven kinds of kerosene-based MPLs were prepared. The hydrodynamic characteristics of MPLs such as the viscosities under different magnetic fields were investigated. The obtained result indicated that the viscosity increases with the growing of the magnetic field and that the type of MPL affects greatly the viscosity. This phenomenon was discussed by observing the magnetic clusters formed in MPL. It was observed that the magnetic clusters are distributed along the magnetic fluxes. An experimental result indicated that the surface roughness varies with polishing time and gets smallest at a certain value of magnetic field strength.

Comparative Analysis of Magneto Rheological Fluid Assisted Electrical Discharge Machining at Stationary and Rotating Conditions of Tool

2018 ◽  
Vol 17 (03) ◽  
pp. 277-290
Author(s):  
Lokesh Upadhyay ◽  
M. L. Aggarwal ◽  
Pulak M. Pandey
Keyword(s):  
Process Parameters ◽  
Material Removal Rate ◽  
Surface Finish ◽  
Material Removal ◽  
Removal Rate ◽  
Mr Fluid ◽  
New Variant ◽  
Magneto Rheological ◽  
Pulse On Time ◽  
Edm Process

A lot of research has been done to improve electric discharge machining (EDM) process to overcome the difficulties of lower material removal and surface finish. In the current study, magneto rheological (MR) fluid was used in place of conventional dielectric to develop a new variant of EDM process. A comparative study of MR fluid assisted EDM at the stationary and rotary conditions of the tool with M2 grade high-speed steel as workpiece has been presented. Investigations have been done to evaluate the effect of various process parameters such as percentage volume Al2O3, pulse on time, duty cycle and discharge current on material removal rate and surface roughness with surface morphology. Higher material removal rate and lower surface finish was obtained in rotary magneto rheological fluid assisted EDM as compared to magneto rheological fluid assisted EDM without rotation under the same processing condition at optimum process parameters.

Effects of Process Parameters on Surface Finish in Laser Solid Freeform Fabrication

2009 ◽  
Author(s):  
Masoud Alimardani ◽  
Mehrdad Iravani Tabrizipour ◽  
Amir Khajepour
Keyword(s):  
Process Parameters ◽  
Surface Finish ◽  
Laser Power ◽  
Solid Freeform Fabrication ◽  
Experimental Investigations ◽  
Main Process ◽  
Layer By Layer ◽  
Freeform Fabrication ◽  
Quality Aspects ◽  
Laser Solid Freeform Fabrication

Laser Solid Freeform Fabrication (LSFF) is a flexible rapid prototyping technique in which a laser beam is used to melt and deposit the injected powder in a layer-by-layer fashion to form 3D components. In this paper, the effects of the main process parameters such as laser power and traverse speed on the surface finish of the parts fabricated using the LSFF process are investigated. Since these process parameters and their variations determine the microstructure and other resultant physical qualities of the fabricated parts, they should carefully be selected to increase the surface quality without compromising other quality aspects of the outcomes. For this purpose, along with the experimental analyses, an experimentally verified 3D time-dependent numerical model is employed to comprehensively study the temperature distributions, thermal stress fields, and their variations resulted from different process parameters and consequently different surface finishes. The experimental investigations are conducted through the fabrications of several thin walls of AISI 303L stainless steel using a fiber laser with a maximum power of 1100 W. The numerical and experimental results show under a constant power feed rate by increasing the process speed while optimizing the laser power, the surface finish of the fabricated parts can improve without compromising the melt pool conditions.

Analysis of magneto rheological elastomers for energy harvesting systems

2020 ◽  
Vol 64 (1-4) ◽  
pp. 439-446
Author(s):  
Gildas Diguet ◽  
Gael Sebald ◽  
Masami Nakano ◽  
Mickaël Lallart ◽  
Jean-Yves Cavaillé
Keyword(s):  
Magnetic Field ◽  
Energy Harvesting ◽  
Shear Strain ◽  
Magnetic Induction ◽  
Magnetic Particles ◽  
Homogeneous Magnetic Field ◽  
Electrical Signal ◽  
Harvesting Systems ◽  
Dc Bias ◽  
Magneto Rheological

Magneto Rheological Elastomers (MREs) are composite materials based on an elastomer filled by magnetic particles. Anisotropic MRE can be easily manufactured by curing the material under homogeneous magnetic field which creates column of particles. The magnetic and elastic properties are actually coupled making these MREs suitable for energy conversion. From these remarkable properties, an energy harvesting device is considered through the application of a DC bias magnetic induction on two MREs as a metal piece is applying an AC shear strain on them. Such strain therefore changes the permeabilities of the elastomers, hence generating an AC magnetic induction which can be converted into AC electrical signal with the help of a coil. The device is simulated with a Finite Element Method software to examine the effect of the MRE parameters, the DC bias magnetic induction and applied shear strain (amplitude and frequency) on the resulting electrical signal.

scholarly journals Shoulder Related Temperature Thresholds in FSSW of Aluminium Alloys

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4375
Author(s):  
David G. Andrade ◽  
Sree Sabari ◽  
Carlos Leitão ◽  
Dulce M. Rodrigues
Keyword(s):  
Heat Generation ◽  
Process Parameters ◽  
Rotational Speed ◽  
Aluminium Alloys ◽  
Spot Welding ◽  
Base Material ◽  
Main Process ◽  
Welding Temperature ◽  
Friction Stir ◽  
Tool Diameter

Friction Stir Spot Welding (FSSW) is assumed as an environment-friendly technique, suitable for the spot welding of several materials. Nevertheless, it is consensual that the temperature control during the process is not feasible, since the exact heat generation mechanisms are still unknown. In current work, the heat generation in FSSW of aluminium alloys, was assessed by producing bead-on-plate spot welds using pinless tools. Coated and uncoated tools, with varied diameters and rotational speeds, were tested. Heat treatable (AA2017, AA6082 and AA7075) and non-heat treatable (AA5083) aluminium alloys were welded to assess any possible influence of the base material properties on heat generation. A parametric analysis enabled to establish a relationship between the process parameters and the heat generation. It was found that for rotational speeds higher than 600 rpm, the main process parameter governing the heat generation is the tool diameter. For each tool diameter, a threshold in the welding temperature was identified, which is independent of the rotational speed and of the aluminium alloy being welded. It is demonstrated that, for aluminium alloys, the temperature in FSSW may be controlled using a suitable combination of rotational speed and tool dimensions. The temperature evolution with process parameters was modelled and the model predictions were found to fit satisfactorily the experimental results.

Procedure to find out the optimal ranges of process parameters for friction stir welding

2021 ◽  
pp. 146442072199314
Author(s):  
Shubham Verma ◽  
Joy Prakash Misra ◽  
Meenu Gupta
Keyword(s):  
Friction Stir Welding ◽  
Process Parameters ◽  
Tilt Angle ◽  
Welding Speed ◽  
Rotational Speed ◽  
Optical Microscope ◽  
Graphical Analysis ◽  
Friction Stir ◽  
Steepest Ascent ◽  
Vertical Milling Machine

The present study deals with the application of sequential procedure (i.e. steepest ascent) to obtain the optimum values of process parameters for conducting friction stir welding (FSW) experiments. A vertical milling machine is modified by fabricating fixture and tool ( H13 material) for performing FSW operation to join AA7039 plates. The steepest ascent technique is employed to design the experiments at different rotational speed, welding speed, and tilt angle. The ultimate tensile strength is considered as a performance characteristic for deciding the optimal levels. The mechanical and metallurgical characteristics of the joints are studied by executing tensile and microhardness tests. It is concluded from the graphical analysis of the steepest ascent technique that the optimal maximum and minimum values are 1812–1325 r/min for rotational speed, 43–26 mm/min for welding speed, and 2°–1.3° for tilt angle, respectively. Besides, optical microscope and scanning electron microscope are utilized for microstructural and fractographic analyses for a better understanding of the process.

scholarly journals A FEM-Based 2D Model for Simulation and Qualitative Assessment of Shot-Peening Processes

Materials ◽  
2021 ◽  
Vol 14 (11) ◽  
pp. 2784
Author(s):  
Georgios Maliaris ◽  
Christos Gakias ◽  
Michail Malikoutsakis ◽  
Georgios Savaidis
Keyword(s):  
Process Parameters ◽  
Material Properties ◽  
Shot Peening ◽  
Qualitative Assessment ◽  
Experimental Investigations ◽  
Elastoplastic Material ◽  
Size Distributions ◽  
User Friendly ◽  
The Impact ◽  
2D Model

Shot peening is one of the most favored surface treatment processes mostly applied on large-scale engineering components to enhance their fatigue performance. Due to the stochastic nature and the mutual interactions of process parameters and the partially contradictory effects caused on the component’s surface (increase in residual stress, work-hardening, and increase in roughness), there is demand for capable and user-friendly simulation models to support the responsible engineers in developing optimal shot-peening processes. The present paper contains a user-friendly Finite Element Method-based 2D model covering all major process parameters. Its novelty and scientific breakthrough lie in its capability to consider various size distributions and elastoplastic material properties of the shots. Therewith, the model is capable to provide insight into the influence of every individual process parameter and their interactions. Despite certain restrictions arising from its 2D nature, the model can be accurately applied for qualitative or comparative studies and processes’ assessments to select the most promising one(s) for the further experimental investigations. The model is applied to a high-strength steel grade used for automotive leaf springs considering real shot size distributions. The results reveal that the increase in shot velocity and the impact angle increase the extent of the residual stresses but also the surface roughness. The usage of elastoplastic material properties for the shots has been proved crucial to obtain physically reasonable results regarding the component’s behavior.

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