{"title":"Determination of Residual Stresses and Surface Roughness Using Chemical Assisted Ball End Magnetorheological Finishing","authors":"Anand Sharma, Mahendra Singh Niranjan","doi":"10.1007/s11665-024-09701-2","DOIUrl":null,"url":null,"abstract":"<div><p>The generation of residual stresses by grinding process on the surface for a soft material results in poor performance and diminished life. Ball end magnetorheological finishing (BEMRF) process is a recently developed process that is effectively used for fine figuring and polishing of a variety of magnetic and non-magnetic materials. In this paper, grinding-induced residual stresses are addressed, and an attempt is made to relieve these residual stresses while achieving high surface finish using chemical assisted ball end magnetorheological finishing (CA-BEMRF) process. The impact of various CA-BEMRF variables on percentage surface roughness reduction and percentage reduction in residual stresses are discussed statistically and graphically. Residual stresses of workpiece surfaces have been measured by using portable x-ray residual stress analyzer. Scanning electron microscopy (SEM) of the finished workpiece before and after CA-BEMRF process is carried out to assess the effects of magnetizing current, tool rotation and working gap on surface topography of machined surface. It has been observed that reduction in residual stress is achieved along with high surface finish on aluminum workpiece surface using CA-BEMRF technique. Significant process parameters affecting the residual stresses and surface roughness during polishing of workpiece are obtained using analysis of variance (ANOVA) and <i>F</i>-test. The optimization problem for maximum percentage reduction in surface roughness and maximum percentage reduction in residual stress is formulated as multiobjective, multivariable, nonlinear optimization problem. Maximum percentage surface roughness reduction and minimum residual stress has been found at magnetizing current 2.3A, rotational speed of tool 550 rpm and working gap of 0.5 mm. Confirmatory experimental tests have been conducted and results obtained were found very close to the predicted outcome.</p></div>","PeriodicalId":644,"journal":{"name":"Journal of Materials Engineering and Performance","volume":"33 and Control","pages":"7781 - 7796"},"PeriodicalIF":2.2000,"publicationDate":"2024-06-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Journal of Materials Engineering and Performance","FirstCategoryId":"88","ListUrlMain":"https://link.springer.com/article/10.1007/s11665-024-09701-2","RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q3","JCRName":"MATERIALS SCIENCE, MULTIDISCIPLINARY","Score":null,"Total":0}
引用次数: 0
Abstract
The generation of residual stresses by grinding process on the surface for a soft material results in poor performance and diminished life. Ball end magnetorheological finishing (BEMRF) process is a recently developed process that is effectively used for fine figuring and polishing of a variety of magnetic and non-magnetic materials. In this paper, grinding-induced residual stresses are addressed, and an attempt is made to relieve these residual stresses while achieving high surface finish using chemical assisted ball end magnetorheological finishing (CA-BEMRF) process. The impact of various CA-BEMRF variables on percentage surface roughness reduction and percentage reduction in residual stresses are discussed statistically and graphically. Residual stresses of workpiece surfaces have been measured by using portable x-ray residual stress analyzer. Scanning electron microscopy (SEM) of the finished workpiece before and after CA-BEMRF process is carried out to assess the effects of magnetizing current, tool rotation and working gap on surface topography of machined surface. It has been observed that reduction in residual stress is achieved along with high surface finish on aluminum workpiece surface using CA-BEMRF technique. Significant process parameters affecting the residual stresses and surface roughness during polishing of workpiece are obtained using analysis of variance (ANOVA) and F-test. The optimization problem for maximum percentage reduction in surface roughness and maximum percentage reduction in residual stress is formulated as multiobjective, multivariable, nonlinear optimization problem. Maximum percentage surface roughness reduction and minimum residual stress has been found at magnetizing current 2.3A, rotational speed of tool 550 rpm and working gap of 0.5 mm. Confirmatory experimental tests have been conducted and results obtained were found very close to the predicted outcome.
期刊介绍：
ASM International''s Journal of Materials Engineering and Performance focuses on solving day-to-day engineering challenges, particularly those involving components for larger systems. The journal presents a clear understanding of relationships between materials selection, processing, applications and performance.
The Journal of Materials Engineering covers all aspects of materials selection, design, processing, characterization and evaluation, including how to improve materials properties through processes and process control of casting, forming, heat treating, surface modification and coating, and fabrication.
Testing and characterization (including mechanical and physical tests, NDE, metallography, failure analysis, corrosion resistance, chemical analysis, surface characterization, and microanalysis of surfaces, features and fractures), and industrial performance measurement are also covered
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