Abstract
In permanent molds, surface finishing is an essential parameter for defining the esthetic features of the product manufactured using them. For obtaining the required surface roughness, various processes are developed in order to reduce the human effort as well as time. In the present work, an effort has been made to optimize the process parameters for nano-surface finishing of hardened AISI 52100 steel that (material) is excessively used in industries for manufacturing of permanent molds. The hardened AISI 52100 steel surfaces have been finished using a magnetorheological solid core rotating tool. The material on which the present finishing process is performed has a hardness of 50 ± 2 HRC which matches the industrial standards of hardness for manufacturing of permanent molds. Response surface methodology is used for the parametric analysis of the magnetorheological fluid-based nanofinishing process. The effects of variation in process parameters on the percentage change in average surface roughness of hardened AISI 52100 steel are analyzed and optimized. The study of change in surface morphology is also analyzed using scanning electron microscopy. Surface cracks formed due to traditional finishing process are eliminated using the present solid rotating core magnetorheological finishing process. The finishing process applied with optimized parameters has been able to finish the workpiece surface up to 20 nm which matches the industrial SPI-A1 finishing standard with 20 min reduction in finishing cycle time.
Similar content being viewed by others
References
Jain NK, Jain VK, Jha S (2007) Parametric optimization of advanced fine-finishing processes. Int J Adv Manuf Technol 34:1191–1213
Maan S, Singh G, Singh AK (2016) Nano-surface-finishing of permanent mold punch using magnetorheological fluid based finishing processes. Mater Manuf Process. https://doi.org/10.1080/10426914.2016.1232823
Mateo M, Carrion-Vilches FJ, Sanes J, Bermudez MD (2011) Surface damage of mold steel and its influence on surface roughness of injection molded plastic parts. Wear 271:2512–2516
Mennig G, Stoeckhert K. (2013) Mold-making handbook. Ohio, USA, 487
Jain VK (2008) Abrasive based nano-finishing techniques: an overview. Mach Sci Technol An Int J 12(3):257–294
Jain VK (2009) Magnetic field assisted abrasive based micro-/nano-finishing. J Mater Process Technol 209:6022–6038
Rhoades LJ (1988) Abrasive flow machining. Manuf Eng 1:75–78
Schuelke T, Grotjohn TA (2012) Diamond polishing. Diam Relat Mater 32:17–26
Jain VK (2008) Abrasive-based nano-finishing techniques. Mach Sci Technol 12:257–294
Sankar MR, Jain VK, Ramkumar J (2016) Nano-finishing of cylindrical hard steel tubes using rotational abrasive flow finishing (R-AFF) process. Int J Adv Manuf Technol 85(9):2179–2187
Singh AK, Jha S, Pandey P (2012) Magnetorheological ball end finishing process. Mater Manuf Process 27(4):389–394
Shinmura T, Takazawa K, Hatano E, Aizawa T (1985) Study on magnetic abrasive process—process principles and finishing possibility. Bull Jpn Soc Precis Eng 19(1):54–55
Kordonski WI, Shorey AB, Tricard M (2006) Magnetorheological jet finishing technology. Trans ASME 128:20–26
Komanduri R (1996) On material removal mechanisms in finishing of advanced ceramics and glasses. CIRP Ann Manuf Technol 45:509–514
Harris DC (2011) History of magnetorheological finishing. Proc Wind Dome Technol Mater SPIE. https://doi.org/10.1117/12.882557
Das M, Jain VK, Ghoshdastidar (2012) Nanofinishing of flat workpieces using rotational–magnetorheological abrasive flow finishing (R-MRAFF) process. Int J Adv Manuf Technol 62:405–420
Mulik RS, Pandey PM (2010) Magnetic abrasive finishing of hardened AISI 52100 steel. Int J Adv Manuf Technol 55(5–8):501–515
Mulik RS, Pandey PM (2011) Ultrasonic assisted magnetic abrasive finishing of hardened AISI 52100 steel using unbonded SiC abrasives. Int J Ref Metals Har Mater 29(1):68–77
Wang AC, Lee SJ (2009) Study the characteristics of magnetic finishing with gel abrasive. Int J Mach Tools Manuf 49:1063–1069
Saraswathamma K, Jha S, Rao PV (2015) Experimental investigation into ball end magnetorheological finishing of silicon. Preci Engi 42:218–223
Chang GW, Wang BH, Hsu RT (2002) Study on cylindrical magnetic abrasive finishing using unbonded magnetic abrasives. Int J Mach Tools Manuf 42:575–583
Bedi TS, Singh AK (2015) Magnetorheological methods for nanofinishing—a review. Part Sci Technol 34(4):412–422
Sidpara A, Jain VK (2012) Experimental investigations into surface roughness and yield stress in magnetorheological fluid based nano-finishing process. Int J Adv Manuf Technol 13(6):855–860
Singh AK, Jha S, Pandey PM (2012) Nanofinishing of a typical 3D ferromagnetic workpiece using ball end magnetorheological finishing process. Int J Mach Tools Manuf 63:21–31
Guo YB, Liu CR (2002) Mechanical properties of hardened AISI 52100 steel in hard machining process. J Manuf Sci Eng. https://doi.org/10.1115/1.1413775
Helieby SOA, Rowe GW (1981) Grinding cracks and microstructural changes in ground steel surfaces. Met Technol 8:58–66
Khurana A, Singh AK, Bedi TS (2017) Spot nanofinishing using ball nose magnetorheological solid rotating core tool. Int J Adv Manuf Technol. https://doi.org/10.1007/s00170-017-0166-8
Sidpara A, Jain VK (2011) Experimental investigations into forces during magnetorheological fluid based finishing process. Int J Mach Tools Manuf 51:358–362
Singh AK, Jha S, Pandey PM (2011) Design and development of nanofinishing process for 3D surfaces using ball end MR finishing tool. Int J Mach Tools Manuf 51:142–151
Pandey S, Kant S, Mishra V, Khatri N, Ramagopal SV (2013) Parametric optimization of ball end magneto rheological finishing process on EN-31. Int J Rece Technol Eng 2(2):2277–3878
Khairy AB (2001) Aspects of surface and edge finish by magnetoabrasive particles. J Mater Process Technol 116:77–83
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Maan, S., Singh, A.K. Nano-surface finishing of hardened AISI 52100 steel using magnetorheological solid core rotating tool. Int J Adv Manuf Technol 95, 513–526 (2018). https://doi.org/10.1007/s00170-017-1209-x
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-017-1209-x