A New Permanent Magnet Type Magnetorheological Finishing Tool for External Cylindrical Surfaces Having Different Outer D
An improved magnetorheological finishing process has been developed with three permanent magnets for nano finishing the external surface of cylindrical workpieces. The cylindrical permanent magnets used in the developed tool are placed at an angle of 90°
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Abstract An improved magnetorheological finishing process has been developed with three permanent magnets for nano finishing the external surface of cylindrical workpieces. The cylindrical permanent magnets used in the developed tool are placed at an angle of 90° from each other. The three cylindrical permanent magnets are positioned in such a way that all three maintain an equal working gap with the surface of cylindrical workpiece. Finite Element (FE) analysis of the entire setup has also been performed in the Maxwell Ansoft V13 software to observe the dispersal of magnetic field density in the working gap. In the current study, the preliminary experimentations have been carried out to evaluate the finishing capability of the present developed tool. Experiments have been conducted over the external cylindrical workpiece made of copper which can be used as an electron discharge machining (EDM) electrode. After the experimentations of 45 min over the entire cylindrical workpiece made of copper, the average surface roughness Ra gets reduced from 224 to 67 nm with negligible surface defects which confirm the finishing performance of the developed finishing tool. Keywords Magnetorheological finishing · Roughness · Peaks · External diameters · Variable · Surface
A. S. Rana (B) RIMT University, Mandi Gobindgarh, Punjab 147301, India e-mail: [email protected] T. S. Bedi Indian Institute of Technology Ropar, Rupnagar, Punjab 140001, India V. Grover Ajay Kumar Garg Engineering College, Ghaziabad, Uttar Pradesh 201009, India © Springer Nature Singapore Pte Ltd. 2021 P. M. Pandey et al. (eds.), Advances in Production and Industrial Engineering, Lecture Notes in Mechanical Engineering, https://doi.org/10.1007/978-981-15-5519-0_17
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1 Introduction In today’s world, industrial components require very precise surface finishing [1, 2]. To attain this specified finished surface, various traditional as well as advanced finishing processes have been developed in the last decade. Conventional finishing processes like grinding, honing, lapping, and ball burnishing, etc., have been developed to acquire surface finishing over various internal or external surfaces. But the traditional finishing processes have limitations that they do not have control over finishing forces [3]. Due to the uncontrollable finishing forces, various problems like surface or subsurface defects, heat generation, etc., persist through these processes [4–6]. To overcome these limitations and acquire good control over the finishing forces, various advanced finishing processes have been flourished in the last two decades [7]. These advanced finishing processes make use of magnetic field for finishing operation. In the presence of magnetic field, abrasives perform the finishing operation in these processes. By regulating the magnitude of magnetic field in these advanced finishing processes, finishing forces acting by the abrasives over the workpiece surface can easily be controlled. A lot of researchers had developed magnetorheologica
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