Magnetorheological finishing process for hard materials using sintered iron-CNT compound abrasives |
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| Authors: | Bongsu Jung Kyung-In Jang Byung-Kwon Min Sang Jo Lee Jongwon Seok |
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| Affiliation: | 1. School of Mechanical Engineering, Chung-Ang University, 221, HeukSeok-Dong, DongJak-Gu, Seoul 156-756, Republic of Korea;2. School of Mechanical Engineering, Yonsei University, 134 ShinChon-Dong, SeoDaeMun-Gu, Seoul 120-749, Republic of Korea;1. Hunan Provincial Key Laboratory of High Efficiency and Precision Machining of Difficult-to-Cut Material, Hunan University of Science and Technology, Xiangtan 411201, PR China;2. Ultraprecision Machining Center, Zhejiang University of Technology, Hangzhou 310014, PR China;3. National Engineering Research Center for High Efficiency Grinding, Hunan University, Changsha 410082, PR China;1. School of Mechatronic Engineering, Changchun University of Technology, Changchun, PR China;2. Department of Industrial, Welding and Systems Engineering, Ohio State University, Columbus, OH 43210, USA;1. Indian Oil Corporation of India Ltd, New Delhi, India;2. Mechanical Engineering Department, Indian Institute of Technology Kanpur, India;3. Mechanical Engineering Department, Indian Institute of Technology Kharagpur, India |
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| Abstract: | The use of magnetorheological fluids for finishing is one of the most promising smart processes for the fabrication of ultra-fine surfaces, particularly three-dimensional millimeter or micrometer structures. This process is not readily applicable to hard-surface materials, like an Al2O3–TiC hard disk slider, if a conventional rotating tool is used. This is due to the rotational speed and the resulting actual impressed abrasion energy limits, and the consequent low efficiency of the material removal rate. In this study, the main mechanism responsible for the decrease of the material removal rate on hard materials for a wheel-type magnetorheological finishing process is examined, both theoretically and experimentally, and a solution to this problem is devised via two approaches. The first uses a rectilinear alternating motion to improve processing conditions, and the second focuses on the use of more effective abrasives, namely magnetizable abrasives made of iron powders sintered with carbon nanotubes, which are new abrasives that have not yet been introduced in the field of surface finishing. Furthermore, it is shown that these abrasives increase the lifetime of consumables (magnetorheological fluid and abrasives) and the material removal rate. |
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