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Assisted Machining Technologies
Published in Helmi Youssef, Hassan El-Hofy, Non-Traditional and Advanced Machining Technologies, 2020
Surface finish has a vital influence on important functional properties such as wear resistance and power losses due to friction on most of the engineering components. Poor surface finish will lead to the rupture of oil films on the peaks of the micro irregularities, which lead to a state approaching dry friction, and results in excessive wear of the contacting surfaces. Therefore, fine finishing processes are employed in machining the surface of many critical machined components to obtain a very high surface finish apart from high dimensional accuracies. Such processes include grinding, lapping, and superfinishing among the traditional methods. These traditional methods could not achieve the requirements of producing precise parts of high surface finish, and free of surface defects and scratches while finishing materials. These cracks can significantly reduce the strength and reliability of the components in working. Although grinding is more efficient for removing material than other finishing methods, it is still difficult to achieve a mirror-like finish. In lapping, it is essential that the abrasive grains be fine and of uniform size. Suitable lapping pressures have to be selected to avoid microcracks on the polished surface. In superfinishing, there are certain limitations especially when applied to complex surface finishing (Jayakumar, 2011).
General-Purpose Abrasive Machine Tools
Published in Helmi Youssef, Hassan El-Hofy, Traditional Machining Technology, 2020
Superfinishing (microhoning) is an abrading process that is used for external surface refining of cylindrical, flat, and spherical-shaped parts. It is not a dimension-changing process but is mainly used for producing finished surfaces of superfine quality. Only a slight amount of stock is removed (2–30 μm), which represents the surface roughness (Figure 4.26). The process of honing involves two main motions, whereas superfinishing requires three or more motions. As a result of these motions, the abrasive path is random and never repeats itself.
Abrasive Finishing Machining Operations
Published in Zainul Huda, Machining Processes and Machines, 2020
Superfinishing is an abrasive finishing operation that involves simultaneous reciprocating motion of a single-bonded abrasive stone against a rotary motion of workpiece (Figure 12.5). An advanced cutting fluid is used in superfinishing that builds up a thin lubricant film between the tool and work surface. Superfinishing produces excellent mirror-like surface finishes with extremely low Ra in the range of 0.01–0.025 μm. Some superfinishing process parameters are presented in Table 12.2.
Effect of Cryo-treatment of wires on machining performance of WEDM
Published in Materials and Manufacturing Processes, 2023
N.E. Arun Kumar, M. Ganesh, A. Suresh Babu, R. Elakkiyadasan
The assessment of the literature revealed that there are only a small number of studies on the analysis of WEDM beneath the brass wire that has undergone cryogenic treatment on MONEL400. Other researchers in this field, except those who used workpieces as cryogenic, evaluated the impact of process parameters using a wire that had been cryogenically treated. The purpose of the current work is to examine the impacts of machining parameters on the surface finish, MRR, and kerf width of MONEL 400 machined under molybdenum, as well as the effects of untreated brass wire and cryogenically treated brass wire. The novelty of this work lies behind in the implementation of cryo-treated brass wire in WEDM on Monel which can improve material removal rate. Further, the research has been conducted to determine the appropriate wire electrode for the precise machining of the Monel 400 alloy and to understand the machining strategies with proper parametric combinations to achieve an improved surface finish, subsequently reducing the time and expense involved in the superfinishing procedure. The relationship between morphological behaviors and parametric deviations is evaluated.
Influence of MQL on performance evaluation of EN19 steel under centreless grinding
Published in Materials and Manufacturing Processes, 2022
N.E. Arun kumar, A. Suresh Babu, M. Subramanian, N Arunkumar
When the wet grinding condition is replaced with the MQL, the energy consumption of the process is reduced with an even lower grinding time. This drastic decrease in the energy consumed from 0.799 kW (wet) to 0.682 kW (MQL) [14.6% reduction] as shown in Fig. 16(a) and the process time taken from 12.35 min (wet) to 11.28 min (MQL) [8.66% reduction] as shown in Fig. 16(b) represent the process optimization, showing a similar graphical pattern as inferred from the cycle time and economic model described by Malkin[26]. Wet grinding may sometimes result in over cooling, leading to the rise in the energy required for the grinding process and grain deformation. When MQL comes into action, the energy required to undergo grinding is far decreased as a result of minimized friction and enhanced cooling effect. The ground workpiece also showed an equivalent surface finish to the wet grinding, reducing the cost associated with the utilized lubricant, need for superfinishing process, and workpiece rejection. Also, the reduction in the wheel degradation phenomenon improvised the grinding wheel life. All these factors combined together to result in the reduction in the grinding cost.
Analysis of particles in magnetorheological polishing fluid for finishing of ferromagnetic cylindrical workpiece
Published in Particulate Science and Technology, 2018
Vishwas Grover, Anant Kumar Singh
Honing is the process which is conventionally used to finish internal surface of cylindrical workpieces having requirement of better geometric and form accuracy (Todd, Allen, and Alting 1994; Schnitzler 2001; Schmitt et al. 2011). It is generally performed after drilling or boring process to attain better finishing surface (Tolinski 2008). But it results some defects with the finish internal surfaces of cylindrical workpieces because of non-control over finishing forces. For performing superfinishing of internal surfaces of cylindrical workpieces, MR-based finishing process such as magnetorheological abrasive flow finishing (MRAFF) (Jha and Jain 2004) has already been developed. But this process has the limitation that it is not capable to significantly finish ferrous material due to the placement of electromagnets outside the workpiece. For performing the superfinishing of internal cylindrical surfaces of ferromagnetic as well as non-ferromagnetic workpieces, a new design of finishing tool based on MR polishing fluid is presented in the manuscript.