Modeling of material removal in magnetic abrasive finishing process with spherical magnetic abrasive powder. (1st July 2020)

• Record Type: Journal Article
• Authors: Gao, Yuewu; Zhao, Yugang; Zhang, Guixiang; Yin, Fengshi; Zhang, Haiyun
• Is Part Of: International journal of mechanical sciences. Volume 177(2020)
• Publication Date: 2020-07-01
• Subjects: Magnetic abrasive finishing -- Diamond particle -- Material removal -- Surface finish; Mechanical engineering -- Periodicals; Génie mécanique -- Périodiques; Mechanical engineering; Maschinenbau; Mechanik; Zeitschrift; Periodicals; 621.05
• DOI: 10.1016/j.ijmecsci.2020.105601
• Languages: English
• ISSNs: 0020-7403

Abstract

Highlights: A bonded type of spherical atomized magnetic abrasive powder is applied in the MAF process. Material removal and surface generation mechanism of stainless steel (SS304) are researched based on MAF test. Theoretical model of the material removal was composed of the mechanical properties of work material and applied process parameters. Through the single factor experiment, to determine the optimized machining conditions of surface roughness for: low working gap (1 mm), low feed rate (1 mm/min), rotational speed (1, 500 rpm) and fine MAPs (150 μm). Abstract: This study describes the application of a magnetic abrasive finishing (MAF) process to yield a fine finish on planar workpiece (SS304). The grinding tool is a flexible abrasive brush using diamond particles embedded in a spherical iron matrix. This bonded type of spherical MAPs was developed via an atomization technology to solve the problem that hard particles were easily thrown from the magnetic field at high rotational speed. Theoretical model of the material removal was composed of the mechanical properties of work material and four applied process parameters such as working gap, rotational speed of magnetic pole, feed rate of workpiece, and size of magnetic abrasive powder (MAP). The magnitude and distribution of generated magnetic flux was simulated by finite element analysis to evaluate the normal pressure of MAP. The single factor experiment was conduct to analyze the relationship between surface roughness reduction and material removal. Scanning electron microscopy was used to understand the effect of different abrasive material on the finished surface of workpiece. Under the same optimum processing condition, diamond MAPs produced a better surface roughness and more material removal than CBN MAPs and alumina MAPs did. The established theoretical model brought out that high material removal corresponds to a fine surface roughness in the MAF process with atomized spherical MAPs. Garphical abstract: Image, graphical abstract