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Effect of optimum process parameters on material removal in rotational-magnetorheological miniature gear profile polishing (R-MRMGPP) process

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Journal of the Brazilian Society of Mechanical Sciences and Engineering Aims and scope Submit manuscript

Abstract

The traditional finishing method causes form inaccuracy in miniature gear profiles due to the transverse grinding line, fine microcrack, claw-mark, burr, pit and thermal distortions. Because of the small space between their teeth, tiny gear can only be polished in a very few ways. This article reports on the new flow restrictor used in rotational-magnetorheological miniature gear profile polishing (R-MRMGPP) process for precise polishing of miniature gear profiles. The response surface method (RSM) is utilized to investigate the effect of key factors on process performance. Further, simulation of finishing forces is conducted using COMSOL® Multiphysics software, which is based on finite element analysis (FEA). The study of finishing forces assists in accurately understanding the processing mechanism. A model is also simulated to determine the depth of indentation produced by an abrasive on SS316L miniature gear tooth profile due to normal finishing forces. Experimental results identified that combining a higher number of finishing cycles, a lower volumetric proportion of iron/abrasive particles, and a higher extrusion pressure is more favourable to obtain high material removal rate (MRR).

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Abbreviations

B :

Magnetic flux density (MFD) (T)

B (x) :

MFD variation in work gap (x) (T)

D g :

Abrasive particles (APs) diameter (μm)

F a :

Axial force (N)

F c :

Centrifugal force (N)

F m :

Normal magnetic force (N)

F t :

Tangential force (N)

H 0 :

Magnetic field strength (A/m)

M :

Iron particles (IPs) magnetization (A-m2/Kg)

m AP :

APs mass (kg)

m ip :

IPs mass (kg)

M s :

Saturation magnetization (A-m2/Kg)

N :

Number of finishing cycles

P :

Extrusion pressure (bar)

r :

Distance of an AP from centre (m)

v :

MRPF APs axial velocity (m/s)

V :

Vol. ratio of IPs/APs

S:

Magnet rotational speed (rpm)

\(\chi_{m}\) :

IPs magnetic susceptibility (m3/kg)

τ :

MRPF shear strength (kPa)

\(\dot{\gamma }\) :

Shear rate

v ip :

IPs Vol. fraction

η :

Non-Newtonian viscosity (kg/(m s))

μ 0 :

Magnetic permeability of free space (Wb/A m)

ω :

Angular velocity (rad/s)

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Acknowledgements

We acknowledge the Science & Engineering Research Board (SERB), New Delhi, India, for their financial support for project No. EEQ/2017/000597 entitled "Fabrication of Prosthetic Im-plants and further Nanofinishing using Magnetic Field Assisted Finishing (MFAF) Process".

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Authors and Affiliations

  1. Department of Mechanical Engineering, Indian Institute of Technology, Guwahati, 781039, India

    Manjesh Kumar & Manas Das

  2. School of Engineering, The University of Edinburgh, Edinburgh, EH8 9YL, UK

    Nan Yu

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Correspondence to Manjesh Kumar.

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Kumar, M., Das, M. & Yu, N. Effect of optimum process parameters on material removal in rotational-magnetorheological miniature gear profile polishing (R-MRMGPP) process. J Braz. Soc. Mech. Sci. Eng. 44, 205 (2022). https://doi.org/10.1007/s40430-022-03515-w

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