Interplay of Process Variables in Magnetic Abrasive Finishing of AISI 1018 Steel Using SiC and Al2O3 Abrasives

This paper investigates the underlying interplay between the key process parameters of magnetic abrasive finishing (MAF) in improving surface quality. The five process parameters considered were the working gap, rotational speed, feed rate, abrasive amount, and abrasive mesh when MAFed independently...

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Bibliographic Details
Published in:Journal of Manufacturing and Materials Processing 2019-06, Vol.3 (2), p.29
Main Authors: Uddin, Mohammad, Santos, Vincent, Marian, Romeo
Format: Article
Language:English
Subjects:
Abrasive finishing
Abrasives
Aluminum oxide
Design of experiments
Energy consumption
Feed rate
Finite element method
Low carbon steels
magnetic abrasive finishing
material removal mechanism
mathematical modeling
Mathematical models
Prediction models
Process parameters
Process variables
Surface properties
surface roughness
Taguchi methods
Variables
Workpieces
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Summary:This paper investigates the underlying interplay between the key process parameters of magnetic abrasive finishing (MAF) in improving surface quality. The five process parameters considered were the working gap, rotational speed, feed rate, abrasive amount, and abrasive mesh when MAFed independently with two abrasive particles—SiC and Al2O3. A series of experiments were conducted with an in-house built MAF tool. Based on the main effect results, a model predicting roughness reduction was developed. Results show that surface quality improvement and the underlying dominant process parameters seem unique to the abrasive type used. When MAFed with SiC, the abrasive quantity and rotational speed influence the most. On the other hand, when MAFed with Al2O3, the trend is different to SiC, i.e., the abrasive mesh size and the working gap are dominant. The prediction model was well validated by independent experiments, indicating its accuracy in estimating and optimizing the process outcome. MAF is a simple process with a complex interplay between parameters. This is very crucial when abrasive type, size, and amount to be used are concerned, which warrants a deeper investigation in terms of underlying dynamics, interactions, and the deformation of abrasive, magnetic, and workpiece materials.
ISSN:2504-4494
2504-4494
DOI:10.3390/jmmp3020029