Study on the Technique of Magnetic Abrasive Finishing in Mould Surface
Recently, advanced technologies in manufacturing industry demand the
production of much more precise and efficient parts. However, tradition
machining involving a single process cannot satisfy the present demand for both
quality and high efficiency simultaneously. The surface quality is determined by
surface roughness and the tress state of the surface. The available traditional
and advanced finishing processes alone are still incapable of producing desired
surface characteristics on complex
Block neodymium magnet geometries, and in exercising in-process
control on finishing action. Thus, a magnetic abrasive finishing process would
meet the demand represents the current trend in the field of manufacturing. The
magnetic abrasive finishing (MAF) process has intrinsically superior finishing
characteristics, especially of complex shapes. A mixture of the iron grain and
aluminum oxide abrasive yielded a superior effect on the surface finish and
material remove rate. Traditional fine finishing operations such as grinding,
lapping, or honing employ a rigid tool that subjects the work piece to
substantial normal stresses which may cause micro cracks resulting in reduced
strength and reliability of the machined part.
A relatively new fine finishing method, magnetic abrasive finishing (MAF)
is an advanced finishing method, the method was originally introduced in the
Soviet Union, with further fundamental research in various countries including
Japan. Nowadays, the study of the magnetic field assisted finishing processes is
being conducted at industrial levels around the world.Magnetic abrasive
finishing (MAF) is an advanced finishing process in which the cutting force is
primarily controlled by the magnetic field. It minimizes the possibility of
micro cracks on the surface of the work piece, particularly in hard brittle
material, due to controlled low forces acting on abrasive particles. This
process is able to produce surface roughness of nanometer range on flat surfaces
as well as internal and external cylindrical surfaces. Via MAF, the initial
surface roughness of 0.25μm Ra can be improved easily to 0.05μm Ra within a few
minutes. And produces neither a deteriorated layer nor micro-cracks on the
finished surface. The MAF process offers many advantages, such as
self-sharpening, self-adaptability, controllability, and the finishing tools
require neither compensation nor dressing. Magnetic abrasive finishing (MAF) is
a processing technology using magnetic abrasive brush formed by magnetic
abrasive grain (MAG) under magnetic field to finish surface of work piece. The
surface is finished by the shearing of the peaks resulting in circular lays
formed by the rotation of the FMAB. In magnetic abrasive finishing (MAF)
process, magnetic force plays a dominant role in the formation of flexible
magnetic abrasive brush (FMAB) and developing abrasive pressure. In order to
produce the magnetic force, the magnetic fields used in MAF include permanent
magnetic field and electromagnetic field.In the magnetic abrasive finishing
(MAF) process, magnetic field is generated using an electromagnetic. Current in
the ranges of 0-10A is passed through the copper coil wound in the form of a
solenoid.
The magnetic field generated within the magnetic core passes through the
magnetic head. Magnetic abrasive is introduced in the gap between the magnetic
heads, i.e., between the N and the S poles. Due to the presence of the magnetic
field, the abrasive align in the direction of the field and the magnetic powders
will be arranged like brushes and the strength and stiffness of the magnetic
brushes can be controlled by the electric current supplied. Shinmura et al. have
studied basic principles of the MAF
Ball Neodymium Magnets process and concluded that the stock removal
and surface finish value (Ra) increase as the magnetic abrasive particle
diameter“D”increases. In order to achieve smooth surface and remove surface
damage, the ferromagnetic particle diameter mast be chosen as a compromise of
material removal rate and resulting surface finishing. In the fifth chapter gets
the optimal diameter“D”of the magnetic abrasive particle by the finishing tests.
Kim et al. have modeled and simulated the MAF process and concluded that the
magnetic flux density in the air-gap is affected greatly by the length of the
air-gap; magnetic flux density increases as the air-gap length decreases. In
addition to magnetic flux density, this paper has studied flat surface finishing
of steel work piece and concluded that rotating speed of magnetic pole, magnetic
abrasive mesh and finishing time etc are the parameters which significantly
influence the change in surface finish value (Ra).Most of the previous research
work has been focused on the finishing characteristics and mechanism from a
macroscopic point of view using the surface roughness profiles as the measure.
However, those approaches do not adequately characterize the behavior of
abrasive cutting edges acting against the surface during the removal process.
This paper examines the acting forces, magnetic field set, magnetic abrasive
grains and experiments by which provides a fundamental understanding of the
process characteristic about MAF.This paper makes theory and test data analyses
about MAF as the discussing focus. The main contribution of this dissertation is
briefly presented as follow:In chapter 2, this paper deals with the theoretical
investigations of the MAF process about the magnetic force. To analyze the
finishing process, a force transducer has been designed and fabricated to
measure forces acting during MAF.A microcosmic model of the process is developed
to analyze the mechanism of the material removal and forces on the work piece
surface.
A theoretical model for material removal is also proposed accounting for
micro cutting by considering a uniform surface profile without statistical
distribution.In chapter 1,the dissertation introduces the background and the
internal and overseas development survey of the research, the summarize about
the technique of the MAF and application foreground of this research are
discussed.In chapter 3, this dissertation discuss the design of the magnetic
field set a copper coil, wound in the form of a solenoid, is used for the
generation of the magnetic field in the core. the alloy of aluminum is used as
the magnetic core material. Magnetic heads are designed such that the stronger
magnetic field is concentrated surrounding the air gap with minimal leakage
between the magnetic heads and the magnetic core.In chapter 4, this dissertation
analyzed grinding mechanism and effect of magnetic abrasive grain in the
magnetic abrasive finishing. Magnetic abrasives grains (MAG) were abrasive tool
of magnetic abrasive technique. Some preparation technique of MAG is introduced.
Blinding and sinter techniques are emphasesly introduced. In some situations, it
is proved that magnetic abrasive grains are produced by blinding technique can
replace the magnetic abrasive grains are produced by sinter technique by
experiments in this study.In chapter 5, the test analyzing of MAF. There are
many main effect factors on MAF, such as Magnetic Flux Density, Rotating Speed
of Tool Magnetic Pole, Grain Diameter of Magnetic Abrasive,
neodymium prices Finishing Time,
Working Gap and Feed Speed of Machine and so on. Based on a series of
experiments, to get the effect law of the diverse factors on finishing quality
and efficiency, this dissertation explore and study these factors which have
important contribution on the finishing quality. Process parameters were
provided to the popularization and application of MAF technology.In chapter
6,the conclusion and expectation.