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A novel wheel-type vibration-magnetorheological compound finishing method

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Abstract

Magnetorheological finishing (MRF) is an important technique to achieve the surface precision of difficult-to-cut materials. In this paper, a wheel-type vibration-magnetorheological compound finishing is proposed in terms of reducing the unidirectional scratch caused by the wheel-type magnetorheological finishing tool and further improving the convergence rate of surface roughness. The vibration-magnetorheological coupling was realized through utilizing designed magnetorheological finishing (MRF) wheel and a nonresonant vibrational device (NRVD). Through the theoretical and experimental analysis, the surface roughness has been verified improved through increasing the normal and tangential forces, which are associated with introducing 2D vibration. The flow and viscoelastic models of the MRP fluid were established based on hydrodynamic lubrication and viscoelasticity theories. Finally, the feasibility of the proposed finishing method was verified by the results of improving surface roughness through designing reasonable processing experiment.

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Data availability

All data generated and analyzed during the study are included in this article.

Code availability

Not applicable.

Abbreviations

\(R\) :

Radius of the MRF wheel

\({h}_{1}\) :

Thickness of the belt

\({h}_{0}\) :

Minimum working gap

\(D\) :

Immersion depth of the belt

\(L\) :

Length of finishing zone

\(W\) :

Effective width generated by a belt

\(S\) :

Finishing zone boundary

\(B\) :

Magnetic flux density in the finishing zone

\(h\) :

Working gap

\({\phi }_{w}\) :

Volume percentage of water

\({\phi }_{c}\) :

Volume percentage of CI particles

\({\phi }_{\mathrm{a}}\) :

Volume percentage of abrasive

\({\phi }_{n}\) :

Volume percentage of nano-silica

\({\phi }_{g}\) :

Volume percentage of glycerol

\({\phi }_{s}\) :

Volume percentage of hexametaponate

\(\tau\) :

Shear stress of the MRP fluid

\({\tau }_{0}\) :

Shear yield stress of the MRP fluid

\({\eta }_{1}\) :

Off-state viscosity of the MRP fluid

\(\dot{\gamma }\) :

Shear rate

\(H\) :

Magnetic field intensity

\({\mu }_{0}\) :

Space permeability

\({M}_{s}\) :

Saturation magnetic field of the magnetic particles

\({\eta }_{0}\) :

Viscosity of the base fluid

\(E\) :

Ideal spring stiffness

\({\eta }_{2}\) :

Ideal Newtonian fluid viscosity

\({G}^{*}\) :

Complex shear modulus

\({G}_{1}\) :

Real part of the complex shear modulus

\({G}_{2}\) :

Imaginary part of the complex shear modulus

\({F}_{N}\) :

Normal force

\({P}_{N}\) :

Normal stress

\({P}_{d}\) :

Hydrodynamic pressure

\({P}_{m}\) :

Magnetization pressure

\({\mu }_{f}\) :

Magneto conductivity of the water

\({\mu }_{p}\) :

Magneto conductivity of magnetic particle

\({h}_{\mathrm{m}0}\) :

Corrected minimum gap

\({h}_{a}\) :

Corrected working gap

\({A}_{1}\) :

Amplitude of the sample moves harmonically along the X-axis

\({f}_{1}\) :

Frequency of the sample moves harmonically along the X-axis

\({U}_{1}\) :

Linear velocity of the sample surface along the X-axis

\(\omega\) :

Rotates angular velocity of the finishing wheel

\({U}_{2}\) :

Linear velocity near the finishing wheel

\({\overline{P} }_{d}\) :

Dimensionless pressure

\({\tau }_{x}\) :

X-axis shear stress

\({dp}_{d}/dx\) :

Pressure gradient

\({\tau }_{1}\left(x,z\right)\) :

Steady shear stress distribution

\({\tau }_{1}\) :

Steady shear stress

\({\gamma }_{x}\) :

X-axis oscillatory shear strain

\({\tau }_{2}\) :

X-axis oscillatory shear stress

\({F}_{\mathrm{x}}\) :

X-axis tangential force

\({A}_{2}\) :

Amplitude of the sample moves harmonically along the Y-axis

\({f}_{2}\) :

Frequency of the sample moves harmonically along the Y-axis

\({\gamma }_{Y}\) :

Y-axis oscillatory shear strain

\({\tau }_{Y}\) :

Y-axis shear stress

\({F}_{Y}\) :

Y-axis tangential force

\(\overline{{F }_{N}}\) :

Theoretical value of the normal force in one period

\(\overline{{F }_{X}}\) :

Theoretical value of the X-axis tangential force in one period

\(\overline{{F }_{Y}}\) :

Theoretical value of the Y-axis tangential force in one period

\(T\) :

Period of vibration

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Funding

This work is supported by the Science and Technology Development Projects of Jilin Province (Grant: 20220201025GX).

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Authors and Affiliations

  1. Jilin Provincial Key Laboratory of Micro-Nano and Ultra-Precision Manufacturing, School of Mechatronic Engineering, Changchun University of Technology, Yan’an Ave 2055, Changchun, Jilin, 130012, People’s Republic of China

    Yan Gu, Bin Fu, Jieqiong Lin, Weidong Zhou, Bing** Yu, Huibo Zhao, Zhen Li & Zisu Xu

  2. Jilin Province Key Laboratory of International Science and Technology Cooperation for High Performance Manufacturing and Testing, School of Mechatronic Engineering, Changchun University of Technology, Yan’an Ave 2055, Changchun, Jilin, 130012, People’s Republic of China

    Yan Gu, Bin Fu, Jieqiong Lin, Weidong Zhou, Bing** Yu, Huibo Zhao, Zhen Li & Zisu Xu

  3. Centre for Precision Manufacturing, DMEM, University of Strathclyde, Glasgow, G1 1XQ, UK

    **uyuan Chen

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  1. Yan Gu
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Contributions

Yan Gu and Bin Fu conducted this study, analyzed the data, and drafted the manuscript. Yan Gu and Jieqiong Lin supervised this work. **uyuan Chen contributed to the literature review. Weidong Zhou, Bing** Yu, Huibo Zhao, Zhen Li, and Zisu Xu provided critical feedback and helped shape the research. All authors have read and agreed to the published version of the manuscript.

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Gu, Y., Fu, B., Lin, J. et al. A novel wheel-type vibration-magnetorheological compound finishing method. Int J Adv Manuf Technol 125, 4213–4235 (2023). https://doi.org/10.1007/s00170-023-11034-8

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