Magnetic Field Assisted Finishing: Methods, Applications and Process Automation

Description

This comprehensive reference text discusses the concepts of the magnetic field assisted finishing processes that ranges from material removal mechanisms, process parameters, and equipment involved to the industry specific applications. The text discusses various aspects of surface finishing including types of material to be finished, types of finishing abrasives and their characteristics for material compatibility, that are different from process specific details. It covers important concepts including magnetic float polishing (MFP), magnetorheological jet finishing (MRJF), magnetorheological abrasive honing (MRAH), and rotational magnetorheological abrasive flow finishing (R-MRAFF). Aimed at graduate students and professionals in the fields of mechanical engineering, aerospace engineering, production engineering, manufacturing, and industrial engineering, this text: Discusses wide range of magnetic field assisted finishing processes in a comprehensive manner. Covers different process parameters by considering their effects on the finishing output. Provides process limitations to achieve optimal yield. Covers numerical explanations for better selection of process parameters. Discusses automation of processes with state-of-the-art technologies. Cover Half Title Series Page Title Page Copyright Page Contents Preface About the Authors Chapter 1: Introduction 1.1. Surface and Its Characteristics 1.1.1. Surface Roughness 1.1.2. Waviness 1.1.3. Lays 1.1.4. Flaws 1.2. Objectives of Good Surface Finish 1.3. Finishing Processes 1.3.1. Traditional Finishing Processes 1.3.1.1. Grinding 1.3.1.2. Lapping 1.3.1.3. Honing 1.3.1.4. Superfinishing 1.3.1.5. Polishing and Buffing 1.3.2. Advanced Finishing Processes 1.3.2.1. Abrasive-Based Advanced Nano-Finishing Processes without External Control of Finishing Forces 1.3.2.2. Abrasive-Based Advanced Nano-Finishing Processes with External Control of Finishing Forces 1.4. Types of Abrasives References Chapter 2: Magnetic Abrasive Finishing 2.1. Introduction 2.2. Essential Elements of MAF 2.2.1. Magnetic Field Generators 2.2.2. Magnetic Abrasive Particles/Ferromagnetic Particle 2.2.3. Abrasive Particles 2.2.4. Lubricants 2.3. Mechanism of Material Removal in MAF 2.4. Types of MAF 2.4.1. Cylindrical MAF 2.4.2. Internal MAF 2.4.3. Plane MAF 2.5. Hybrid MAF Processes 2.5.1. Electrolytic MAF 2.5.2. Vibration-Assisted MAF 2.6. Factors Affecting MAF 2.6.1. Magnetic Abrasive Type and Its Composition 2.6.2. Abrasive Particle Size 2.6.2.1. Effect of Abrasive Particle Size on Surface Roughness 2.6.2.2. Effect of Abrasive Particle Size on Material Removal 2.6.3. Magnetic Flux Density 2.6.4. Working Gap 2.6.5. Rotational Speed 2.6.6. Axial Vibration 2.6.7. Workpiece Material 2.6.8. Cutting Fluids (Lubricants) 2.6.9. Finishing Time 2.7. Advantages of MAF 2.8. Limitations of MAF 2.9. Applications of MAF References Chapter 3: Magnetorheological Finishing 3.1. Magnetorheological Fluid 3.2. Magnetorheological Finishing 3.2.1. Process Parameters of MRF 3.2.1.1. Magnetic Flux Density 3.2.1.2. Carbonyl Iron Particle Concentration 3.2.1.3. Abrasive Particle Concentration 3.2.1.4. Carrier Wheel Speed 3.3. Ball End Magnetorheological Finishing 3.3.1. Mechanism of Material Removal in BEMRF Process 3.3.2. BEMRF Tool 3.3.3. Process Parameters of BEMRF. 3.3.3.1. Electromagnet Current 3.3.3.2. Working Gap 3.3.3.3. Spindle Speed 3.3.4. Mathematical Modeling of BEMRF Process 3.3.5. Closed-Loop Control of BEMRF Process 3.4. Magnetorheological Jet Finishing 3.5. Applications References Chapter 4: Magnetorheological Abrasive Flow Finishing 4.1. Magnetorheological Abrasive Flow Finishing 4.1.1. Mechanism of Material Removal in MRAFF Process 4.1.2. Experimental Setup 4.2. Process Parameters of MRAFF 4.2.1. Magnetic Flux Density 4.2.2. Extrusion Pressure 4.2.3. Number of Finishing Cycles 4.2.4. Relative Size of CIP and Abrasive Particles 4.3. Modeling and Simulation of MRAFF Process 4.4. Rotational MRAFF 4.4.1. Mechanism of Material Removal in R-MRAFF Process 4.4.2. Process Parameters of R-MRAFF 4.5. Applications References Chapter 5: Process Automation of Magnetic Field Assisted Finishing 5.1. Introduction 5.2. Process Parameters and Their Characterization 5.2.1. Process Parameters of Magnetic Abrasive Finishing (MAF) 5.2.2. Process Parameters of Magnetorheological Finishing (MRF) 5.2.3. Process Parameters of Magnetorheological Abrasive Flow Finishing (MRAFF) 5.3. Motion Parameters and Control 5.3.1. Types of Drives and Actuators 5.3.1.1. State-of-the-Art Availability of Drives 5.3.2. Number of Axes 5.3.3. Motion Options in Each Process 5.3.3.1. Motion Configuration of MAF and Its Variants 5.3.3.2. Motion Configuration of MRF and Its Variants 5.3.3.3. Motion Configuration of MRAFF and R-MRAFF 5.4. Control Hardware and Control Panel 5.4.1. Control Hardware 5.4.2. Control Panel 5.5. User Interface and Programming 5.5.1. Automatic Mode 5.5.2. Manual Mode 5.6. Feedback Systems 5.6.1. Equipment 5.6.2. Data Acquisition and Analysis 5.6.3. Control Action 5.7. Automation of BEMRF Process: A Case Study 5.7.1. Physical Setup of BEMRF 5.7.2. Software and Graphical User Interface 5.7.3. Controller and Finishing Results 5.7.4. Part-Program–Based Control of the BEMRF Process 5.7.4.1. The Surface Finishing Cycle and Associated Part-Program 5.7.4.2. Workpiece Cleaning Cycle 5.7.4.3. Roughness Measurement Cycle 5.7.4.4. Integrated Part-Program for All Three Cycles 5.7.5. Testing and Results of Automation of BEMRF Process References Index