ABSTRACT

Magnetic abrasive finishing is a prevalent advanced method which by applying gentle forces using flexible magnetic abrasives for removing surface irregularities, provides a micro/nano range of defect-free surface finish. During magnetic abrasive finishing, magnetic forces allow the flexible magnetic abrasive particles to shear off the material from the surface in the form of microchips. During the finishing of a material having high hardness value such as titanium alloy, Nimonic alloy, and ceramics, etc., it is necessary to choose a proper magnetic abrasive considering the rate of improvement required in the surface finishing. In this research work, a new magnetic abrasive has been developed, which is suitable for finishing of Ti-6Al-4 V. The sintering method was used to develop the magnetic abrasive, and hence the developed magnetic abrasive has been named as-sintered magnetic abrasive (SMA). A mixture of abrasive powder of aluminium oxide and silicon oxide (Al₂O₃-SiO₂) with carbonyl iron particles (ferromagnetic material) has been taken as components of sintered magnetic abrasive. The authors have studied the morphology of the sintered magnetic abrasive by scanning electron microscopy (SEM), energy dispersive spectrum (EDS), and structure by the X-ray diffraction technique. The findings reveal that the abrasives were uniformly and tightly rooted in the carbonyl iron particles. Also, magnetic abrasive finishing roughness studies on the Ti-6Al-4 V workpiece were carried to evaluate the performance of SMA. Change in the surface roughness from R_a = 1.14 µm to R_a = 0.85 µm was observed and atomic force microscopy (AFM) of the finished surface confirms an excellent finishing effect by the developed sintered magnetic abrasive on Ti-6Al-4 V during magnetic abrasive finishing.

摘要

磁性研磨剂是一种普遍使用的先进方法，通过使用柔性磁性研磨剂施加轻微的力来去除表面不规则性，可提供微/纳米范围的无缺陷表面处理。在磁性研磨剂抛光过程中，磁力使柔性磁性研磨剂颗粒以微芯片的形式从表面切下材料。在对诸如钛合金，镍合金和陶瓷等具有高硬度值的材料进行精加工时，有必要考虑表面精加工所需的改善率来选择合适的磁性磨料。在这项研究工作中，开发了一种适用于Ti-6Al-4 V精加工的新型磁性磨料。使用烧结方法开发了磁性磨料，因此开发的磁性磨料已被称为烧结磁性磨料（SMA）。氧化铝和氧化硅（Al具有羰基铁颗粒（铁磁性材料）的₂ O ₃ -SiO ₂）已被用作烧结磁性磨料的成分。作者通过扫描电子显微镜（SEM），能量色散谱（EDS）和X射线衍射技术研究了烧结磁性磨料的形貌。该发现表明，磨料均匀且紧密地扎在羰基铁颗粒中。另外，还对Ti-6Al-4 V工件进行了磁性研磨精加工粗糙度研究，以评估SMA的性能。表面粗糙度从R _a  = 1.14 µm到R _a的变化 观察到= 0.85 µm，并且精加工表面的原子力显微镜（AFM）证实了在磁研磨加工过程中，已开发的烧结磁研磨剂在Ti-6Al-4 V上具有优异的精加工效果。