اثر هم‌افزایی میدان مغناطیسی دوار و ارتعاشات فراصوت در پرداخت‌کاری جریان ساینده مگنتورئولوژیکال

نوع مقاله : مقاله پژوهشی

نویسندگان

1 گروه مهندسی مکانیک، دانشکده فنی و مهندسی، دانشگاه میبد، میبد، ایران.

2 گروه مهندسی مکانیک، دانشکده مهندسی مکانیک، دانشگاه صنعتی امیرکبیر، تهران، ایران

چکیده

در این مطالعه، از میدان مغناطیسی دوار و ارتعاشات فراصوت به‌عنوان راه‌حلی مؤثر برای رفع چالش‌های فرآیند پرداخت‌کاری جریان ساینده مگنتورئولوژیکال استفاده شده است. برای تحقق این هدف، ابتدا یک نمونه صنعتی از فرآیند پرداخت‌کاری جریان ساینده مگنتورئولوژیکال طراحی و ساخته شد. پس از آماده‌سازی سیال پولیشکاری مگنتورئولوژیکال، میدان مغناطیسی دوار اعمال شد و در نهایت، ارتعاشات فراصوت در جهت عمود بر جریان سیال به قطعه‌کار اضافه گردید. برای ارزیابی عملکرد روش پیشنهادی، تأثیر زمان پردازش بر سه شاخصِ نسبت زبری سطح، نرخ پرداخت‌کاری و نرخ برداشت ماده در لوله‌های آلیاژ آلومینیوم 2024 بررسی شد. نتایج نشان داد که در ۱۰ دقیقه نخست پردازش، علاوه بر کاهش نسبت زبری سطح، نرخ پرداخت‌کاری و نرخ برداشت ماده نیز افزایش یافت؛ اما تداوم فرآیند، به‌دلیل اثرات مخرب ذرات ساینده، منجر به افزایش مجدد زبری سطح شد. تصاویر میکروسکوپی نه‌تنها این یافته‌ها را تأیید کردند، بلکه آشکار ساختند که روش پیشنهادی در شرایط بهینه، علاوه بر ایجاد سطحی یکنواخت، زبری سطح داخلی لوله‌ها را تا %98 کاهش داده است. در نتیجه، این روش به‌عنوان راهکاری کارآمد برای پرداخت و پلیسه‌گیری سطوح داخلی، به‌ویژه در لوله‌های بلند، چشم‌اندازی امیدبخش ارائه می‌دهد.

کلیدواژه‌ها

موضوعات

عنوان مقاله [English]

Synergistic Effect of Rotating Magnetic Field and Ultrasonic Vibrations in Magnetorheological Abrasive Flow Finishing

نویسندگان [English]

  • Yahya Choopani 1
  • Mohsen Khajehzadeh 2
  • Mohammad Reza Razfar 2
1 Department of Mechanical Engineering, Meybod University, Meybod, Iran
2 Mechanical Engineering Department, Amirkabir University of Technology, Tehran, Iran
چکیده [English]

This study employed rotating magnetic fields and ultrasonic vibrations as an effective solution to overcome the limitations associated with the magnetorheological abrasive flow finishing (MRAFF) process. To this end, first, an industrial prototype of the MRAFF setup was designed and fabricated. After preparing the magnetorheological polishing (MRP) fluid, a rotating magnetic field was applied, and subsequently, ultrasonic vibrations were applied to the workpiece in a direction perpendicular to the fluid flow. In order to evaluate the efficiency of the proposed technique, the effect of processing time on three indices, i.e., surface roughness rate, finishing rate, and material removal rate, in aluminum alloy 2024 tubes was investigated. The results indicated that during the first 10 minutes of processing, besides a decrease observed in the surface roughness ratio, the finishing rate and material removal rate also increased; however, due to the destructive effects of abrasive particles, the continuation of the process caused a re-increase in the surface roughness. Microscopic images not only confirmed these findings but also indicated that under optimal conditions, in addition to creating a uniform surface, the proposed technique reduced the roughness of the inner surface of the tubes by 98%. As a result, this method offers a promising prospect as an efficient solution for finishing and deburring inner surfaces, especially in longer tubes.

کلیدواژه‌ها [English]

  • Rotating Magnetic Field
  • Ultrasonic Vibrations
  • Surface Roughness Ratio
  • Finishing Rate
  • Material Removal Rate

مراجع

[1] A. Fletcher, J. Hull, J. Mackie, S. Trengove, Computer modelling of the abrasive flow machining process, in: Proceedings of International Conference on Surface Engineering: Toronto, Canada, (1990) 592-601.
[2] P. Davies, A. Fletcher, The assessment of the rheological characteristics of various polyborosiloxane/grit mixtures as utilized in the abrasive flow machining process, Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 209(6) (1995) 409-418.
[3] R. Williams, K. Rajurkar, Stochastic modeling and analysis of abrasive flow machining, Trans the American Society of Mechanical Engineers (ASME), Journal of Engineering for Industry, 114 (1) (1992) 74–81.
[4] M. Sarkar, V. Jain, Nanofinishing of freeform surfaces using abrasive flow finishing process, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 231(9) (2017) 1501-1515.
[5] Y. Fu, X. Wang, H. Gao, H. Wei, S. Li, Blade surface uniformity of blisk finished by abrasive flow machining, The International Journal of Advanced Manufacturing Technology, 84(5) (2016) 1725-1735.
[6] D. Jung, W. Wang, S. Hu, Microscopic geometry changes of a direct-injection diesel injector nozzle due to abrasive flow machining and a numerical investigation of its effects on engine performance and emissions, Proceedings of the Institution of Mechanical Engineers, Part A: Journal of Power and Energy, 222(2) (2008) 241-252.
[7] J. Guo, C. Song, Y. Fu, K.H. Au, C.W. Kum, M.H. Goh, T. Ren, R. Huang, C.-N. Sun, Internal surface quality enhancement of selective laser melted inconel 718 by abrasive flow machining, Journal of Manufacturing Science and Engineering, 142(10) (2020) 101003.
[8] N. Dixit, V. Sharma, P. Kumar, Research trends in abrasive flow machining: A systematic review, Journal of manufacturing Processes, 64 (2021) 1434-1461.
[9] G. Venkatesh, D. Sood, A.K. Sharma, On surface integrity of Al 2014 alloy finished by ultrasonic assisted abrasive flow machining, in:  IOP Conference Series: Materials Science and Engineering, IOP Publishing, 346 (2018) 012057.
[10] Q. Wang, M.S. Vohra, S. Bai, S.H. Yeo, Rotary ultrasonic-assisted abrasive flow finishing and its fundamental performance in Al6061 machining, The International Journal of Advanced Manufacturing Technology, 113(1) (2021) 473-481.
[11] S. Singh, H. Shan, Development of magneto abrasive flow machining process, International Journal of Machine Tools and Manufacture, 42(8) (2002) 953-959.
[12] M. Das, V. Jain, P. Ghoshdastidar, Fluid flow analysis of magnetorheological abrasive flow finishing (MRAFF) process, International Journal of Machine Tools and Manufacture, 48(3-4) (2008) 415-426.
[13] Y. Choopani, M. Khajehzadeh, M.R. Razfar, Experimental investigations into the nano-finishing of Al2024 tubes using the rotational-magnetorheological abrasive flow finishing (R-MRAFF) process, Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 236(6) (2022) 2545-2557.
[14] Y. Choopani, M.R. Razfar, M. Khajehzadeh, M. Khosrojerdi, Design and development of ultrasonic assisted-rotational magnetorheological abrasive flow finishing (UA-RMRAFF) process, Applied Acoustics, 197 (2022) 108950.
[15] N. Dixit, V. Sharma, P. Kumar, Experimental investigations into ultrasonic assisted magnetic abrasive flow machining process, Materials and Manufacturing Processes, 38(10) (2023) 1291-1306.
[16] M.R. Shabgard, A.A. Amini Khasraghi, A. Gholipoor, Experimental investigation of the effects of work piece hardness and abrasive particle size in rotational abrasive flow Machining, Modares Mechanical Engineering, 18(5), (2018) 75-83, (in Persian).
[17] M.R. Shabgard, F. Arabzadeh Tabriz, A. Gholipoor, Experimental study of the effects of abrasive particle size and work piece hardness in Magnetic abrasive flow Machining, Modares Mechanical Engineering, 16(8) (2016) 131-138, (in Persian).
[18] M. Aamir, M. Tolouei-Rad, K. Giasin, A. Vafadar, Machinability of Al2024, Al6061, and Al5083 alloys using multi-hole simultaneous drilling approach, Journal of Materials Research and Technology, 9(5) (2020) 10991-11002.
نشریه مهندسی مکانیک امیرکبیر
دوره 57، شماره 4
تیر 1404
صفحه 453-472

فایل ها

هم رسانی

ارجاع به این مقاله

آمار