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Experimental Characterization of Surface Roughness UsingMagnetorheological Abrasive Flow Finishing Process on AISI D3 Steel
Published in Springer
Volume: 5.0
Issue: 3.0
Pages: 1.0 - 16.0
The main objective of the present work is to develop a novel finishing process to polish the die steel materials with the use of magnetorheological fluid and also to investigate the effects of the input process parameters such as concentration of CIPs and abrasive particles (Al2O3), magnetizing current, speed of rotating tool, feed rate, working gap and hardness of workpiece on the response of surface roughness (Ra). In view of this, a novel MR fluid-based finishing setup is developed to characterize the process performance. Based on the method of full factorial design with two levels, 64 experiments are conducted on CNC vertical machining center with the customized setup. The results of the response are formulated by applying the ANOVA, and a mathematical model is established using linear regression to predict the response Ra. Capacity of the newly developed process is proven to achieve the surface finish on the hardness of 65 HRC D3 materials from 0.156 to 0.081 µm with the duration of polishing 10 min. The result of the experiments reveals that the major contributions of the parameters to improve the surface finish are working gap, magnetized current, and the hardness of the work piece, and followed by the rotating speed of tool, the ratio of CIP to abrasive, and feed rate of the work piece. The average percentage deviation between the predicted and observed surface roughness values is 3.56 within the band of 5% error. Scanning electron microscopy (SEM) is applied to characterize the integrity of the surface and testifies the efficacy of the developed MR fluid process to obtain a nano-level surface finish on the die steel material.
About the journal
JournalData powered by TypesetJournal of Bio- and Tribo-Corrosion
PublisherData powered by TypesetSpringer
Open AccessNo