Magnetic Field Assisted Finishing: Methods, Applications and Process Automation

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