Micromachining the Aluminium Tubes Using Abrasive Finishing in Alternating Magnetic Field

Subject Areas : Journal of Simulation and Analysis of Novel Technologies in Mechanical Engineering

Reza Abedinzadeh ¹ , Rasoul Gorji ²

1 - Department of Mechanical Engineering, Khomeinishahr Branch, Islamic Azad University, Isfahan, Iran
2 - Department of Mechanical Engineering, Khomeinishahr Branch, Islamic Azad University, Isfahan, Iran

Received: 2017-11-18 Accepted : 2018-03-11 Published : 2017-11-01

Keywords: Roughness, Taguchi, ANOVA, Abrasive finishing, Alternating magnetic,

Abstract :

This study introduced a method based on magnetic field assisted finishing mechanism for micromachining the inner surfaces of Aluminum tubes. In this approach, using the alternating magnetic field of an AC electromotor, abrasive particles were formed as Magnetic Rods (Magnetic Clusters) and surface micromachining was carried out by the dynamic particular pattern made by an alternating magnetic field. The aim of this process was to improve machining efficiency of Aluminum tubes based on surface roughness and dimensional tolerance. Continuously, the effects of parameters such as tube inner diameter, abrasive particles weight, current frequency and machining time on changes of surface roughness were assessed by DOE technique. Taguchi standard orthogonal method (L9 (34)) was used to analyze the process factors. Moreover, the output results derived from experiments were analyzed by two most widely used analytical techniques including Signal to Noise ratio (S/N) and Analysis of Variance (ANOVA). Finally, by considering the results of analysis and plotted graphs, abrasive particles weight and current frequency were identified as significant factors and the optimum conditions of process including tube inner diameter of 55 mm, abrasive particles weight of 1 g, frequency of 40 Hz and machining time of 60 s were obtained.

References:

[1] M. Givi, A.F. Tehrani, and A. Mohammadi, “Polishing of the aluminum sheets with magnetic abrasive finishing method,” Int. J. Adv. Manuf. Tech., vol. 61, pp. 989-98, 2012.

[2] V. Grover, and A.K. Singh, “A novel magnetorheological honing process for nano-finishing of variable cylindrical internal surfaces,” Mater. Manuf. Process., vol. 32, pp. 573-580, 2017.

[3] A. Manna, and A. Kundal, “Micro machining of nonconductive Al₂O₃ ceramic on developed TW-ECSM setup,” Int. J. Manuf. Mater. Mech. Eng., vol. 1, pp. 46-55, 2011.

[4] K. Rakhimyanov, and I. Semenova, “Surface state control by ultrasonic plastic deformation at the final machining stage,” Mater. Manuf. Process., vol. 31, pp. 764-9, 2016.

[5] P. Saraeian, H. Soleimani Mehr, B. Moradi, H. Tavakoli, and O. Khalil Alrahmani, “Study of magnetic abrasive finishing for AISI321 stainless steel,” Mater. Manuf. Process., vol. 31, pp. 2023-9, 2016.

[6] C. Vipin, and M. Shukla & Pulak, “Experimental investigations into sintering of magnetic abrasive powder for ultrasonic assisted magnetic abrasive finishing process,” Mater. Manuf. Process., vol. 32, pp. 108-14, 2017.

[7] G. Singh, A.K. Singh, and P. Garg, “Development of Magnetorheological finishing process for external cylindrical surfaces,” Mater. Manuf. Process., vol. 32, pp. 581-8, 2017.

[8] M. Sushil, K. Vinod, and K. Harmesh, “Experimental investigation and optimization of process parameters of Al/SiC MMCs finished by abrasive flow machining,” Mater. Manuf. Process., vol. 30, pp. 902-11, 2015.

[9] N. Francis, K. Viswanadhan, and M. Paulose, “Swirling abrasive fluidized bed machining: Effect of process parameters on machining performance,” Mater. Manuf. Process., vol. 30, pp. 852-7, 2015.

[10] J. Sheikh-Ahmad, and J. Mohammed, “Optimization of process parameters in diamond abrasive machining of carbon fiber-reinforced epoxy,” Mater. Manuf. Process., vol. 29, pp. 1361-6, 2014.

[11] R. Ferreira, D. Carou, C. Lauro, and J. Davim, “Surface roughness investigation in the hard turning of steel using ceramic tools,” Mater. Manuf. Process., vol. 31, pp. 648-52, 2016.

[12] S.M. Ji, Y.M. Xu, G.D. Chen, and  M.S. Jin, “Comparative study of magnetic abrasive finishing in free-form surface based on different polishing head,” Mater. Sci. Forum, vol. 675, pp. 593-596, 2011.

[13] K. Judal, and V. Yadava, “Modeling and simulation of cylindrical electrochemical magnetic abrasive machining process,” Mach. Sci. Technol., vol. 18, pp. 221-50, 2014.

[14] S. Jayswal, V. Jain, and P. Dixit, “Modeling and simulation of magnetic abrasive finishing process,” Int. J. Adv. Manuf. Tech., vol. 26, pp. 477-90, 2005.

[15] C.T. Lin, L.D. Yang, and H.M. Chow, “Study of magnetic abrasive finishing in free-form surface operations using the Taguchi method,” Int. J. Adv. Manuf. Tech., vol. 34, pp. 122-30, 2007.

[16] J. Kwak, and T. Kwak, “Parameter optimization in magnetic abrasive polishing for magnesium plate,” 2nd Int. Conf. Comput. Eng. Technol., vol. 5, pp. 544-547, 2010.

[17] B. Girma, S.S. Joshi, M. Raghuram, and R. Balasubramaniam, “An experimental analysis of magnetic abrasives finishing of plane surfaces,” Mach. Sci. Technol., vol. 10, pp. 323-40, 2006.

[18] Y. Wang, and D. Hu, “Study on the inner surface finishing of tubing by magnetic abrasive finishing,” Int. J. Mach. Tools Manuf., vol. 45, pp. 43-9, 2005.

[19] P.S. Kang, L. Singh, and J.S. Gill, “Finishing of SUS 304 stainless steel bent tubes using magnetic abrasive finishing,” Mechanica. Confab. Int. J., vol. 2, pp. 123-30, 2013.

[20] J. Wu, Y. Zou, and H. Sugiyama, “Study on finishing characteristics of magnetic abrasive finishing process using low-frequency alternating magnetic field,” Int. J. Adv. Manuf. Tech., vol. 85, pp. 585-94, 2016.

[21] X.G. Yao, Y.H. Ding, G. Ya, W.W. Liu, and Y. Zhang, “Study of finishing mechanism for internal surface using magnetic force generated by rotating magnetic field,” Key Eng. Mat., vol. 416, pp. 406-410, 2009.

[22] D.C. Montgomery, Design and analysis of experiments; John Wiley & Sons, 2017.

[23] S. Ahmad, S. Gangwar, P.C. Yadav, and D. Singh, “Optimization of process parameters affecting surface roughness in magnetic abrasive finishing process,” Mater. Manuf. Process., pp. 1-7, 2017.

[24] G.S. Gandhi, and L. Singh, “Internal finishing of thick cylinder SUS 304 steel tubes using magnetic abrasive finishing setup,” Int. J. Mech. Civil Eng., vol. 2, 2013.