Simulation For The Prediction Of Surface-accuracy In Magnetic Abrasive Machining

Journal of ELSEVIER Journal of Materials Processing Technology 53 (1995) 630 642 Materials Processing Technology Simulation for the prediction of surface-accuracy in magnetic abrasive machining J e o n g - D u Kim*, Min-Seog Choi Department of Precision Engineering & Mechatronics, Korea Advanced Institute of Science and Technology, 373-1, Kusong-dong, Yusong-yu, Taejon 305-701, South Korea Received 21 March 1994 Industrial Summary A new machining technique, magnetic abrasive machining which uses magnetic force as a machining pressure, has been developed recently for the efficient and precision finishing of surfaces. The process is controllable because the machining pressure is controlled only by the current that is input to the coil of solenoid, but it needs the monitoring of the surface roughness for the automation of the process and for the achieving of machining efficiency by preventing over-finishing of the surface. For this, in the present study, the surface roughness is predicted as a function of finishing time by a model that has been derived from the removed volume of material. Thus, it is possible, from the surface-roughness model, to predict the time when existing scratches are completely removed. The simulation results are confirmed by comparing them with the experimental results of previous papers. Keywords: Magnetic abrasive machining; Simulation, Surface roughness, Machining scratch Nomenclature Aa~ Am B Bs D F f H Ha cross-sectional area of the air-gap and magnet magnetic flux density saturated magnetic flux density mean diameter of the magnetic particles total force acting on the machining region force acting on a magnetic particle magnetic field strength of the magnetic abrasives magnetic field strength in the air gap * Corresponding author. 0924-0136/95/$09.50 (C; 1995 Elsevier Science S.A. All rights reserved SSDI 0 9 2 4 - 0 1 3 6 ( 9 4 ~ 0 1 7 5 3 - N J.-D. Kim, M.-S. Choi / Journal of Materials Processing Technology 53 (1995) 630-642 H c Hmt I la, lm M m N n c P Ra Ro Rcrl t /3 w Af Am ~crt 2O 20~ Po ~/rs 631 coercive force workpiece hardness input current length of the air-gap and magnet total volume of material removed volume of material removal by a magnetic particle number of magnetic particles acting on the machining region simultaneously the number of grain edges of a magnetic particle acting simultaneously on the surface number of turns of the coil machining pressure supplied by the mag