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Nanofinishing of 3D surfaces by automated five-axis CNC ball end magnetorheological finishing machine using customized controller

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posted on 2024-10-25, 11:20 authored by Zafar Alam, Faiz IqbalFaiz Iqbal, Sivasankar Ganesan, SUNIL JHA

Ball end magnetorheological finishing (BEMRF) is a novel method for nanofinishing of ferromagnetic as well as nonmagnetic materials. With increasing demands of precision finished products in various markets, the quality of surface finish and production rate are of prime importance. For products having complex geometries, this need intensifies as the manual finishing methods are incapable of producing uniform finish throughout the complex geometry of the surface. This paper describes the finishing of 3D surfaces using five-axis CNC BEMRF process in a fully automated manner such that a uniform finish is obtained throughout the workpiece. This eliminates the labor-intensive efforts and the subjective errors involved in manual finishing operations and increases the production rate of the finished products. A customized five-axis CNC controller is developed that enables the sequential and precise control of motion as well as process parameters in the BEMRF machine. The magnetizing current which governs the forces responsible for finishing in BEMRF process is controlled in-process through CNC part program using a specially defined “E” code for magnetizing current. A dedicated graphical user interface is also developed in Visual C# for the control of BEMRF process, enabling the user to make use of BEMRF machine without going into the complexities of the system. Using the customized five-axis CNC controller, automated finishing of a freeform mild steel workpiece is done. The finishing results obtained by the automated five-axis BEMRF machine shows uniformly finished surface profile (up to order of nanometer) on the mild steel test specimen. 

History

School affiliated with

  • School of Engineering (Research Outputs)

Publication Title

The International Journal of Advanced Manufacturing Technology

Volume

100

Pages/Article Number

1031–1042

Publisher

Springer

ISSN

0268-3768

eISSN

1433-3015

Date Accepted

2017-12-18

Date of First Publication

2018-01-18

Date of Final Publication

2019-02-19

Open Access Status

  • Not Open Access

Publisher statement

This version of the article has been accepted for publication, after peer review (when applicable) and is subject to Springer Nature’s AM terms of use, but is not the Version of Record and does not reflect post-acceptance improvements, or any corrections. The Version of Record is available online at: https://doi.org/10.1007/s00170-017-1518-0 Springer Nature Terms of Use for accepted manuscripts of subscription articles, books and chapters apply: https://www.springernature.com/gp/open-science/policies/accepted-manuscript-terms

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