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Investigation on magnetorheological shear thickening finishing (MSTF) with radially slotted magnetic pole for free-form surface

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Abstract

Free-form surface is widely applied in the manufacturing industries due to its excellent geometric characteristics. Surface finishing of free-form surface is a critical manufacturing process to meet the target quality requirement. In this work, a magnetorheological shear thickening finishing (MSTF) method was employed with the designed finishing tool and the developed MSTF media for the finishing of a typical free-form surface, i.e., Sine surface. The finishing tool was designed as a slotted cylindrical permanent magnetic pole with radial magnetization. The magnetic pole was fabricated to dominate MSTF performance of the finishing media. To obtain sufficiently large magnetic flux density and magnetic field gradients in the finishing zone, finite element analysis (FEA) was used to optimize the dimension of the finishing tool. The MSTF principle was illustrated in detail. The mathematical model of the material removal was established. Finishing experiments were conducted on the SUS304 Sine surface using the developed MSTF media. The effects of finishing parameters on surface roughness were evaluated quantitatively. The results showed that the material was uniformly removed across the entire Sine surface with over 87% improvement in surface roughness (Sa). It is quite potential for the surface finishing free-form surface in a wide manufacturing industrial applications.

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All data generated or analyzed during this study are included in this published article.

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Funding

This work was financially supported by the National Natural Science Foundation of China (Grant Nos. 51875329 and 51905323), Taishan Scholar Special Foundation of Shandong Province (Grant No. tsqn201812064), Shandong Provincial Natural Science Foundation, China (Grant No. ZR2017MEE050), Shandong Provincial Key Research and Development Project, China (Grant No. 2018GGX103008), Scientific Innovation Project for Young Scientists in Shandong Provincial Universities (Grant No. 2019KJB030), and Key Research and Development Project of Zibo City (Grant No. 2019ZBXC070).

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Authors and Affiliations

  1. School of Mechanical Engineering, Shandong University of Technology, 266 Xincun West Road, Zibo, Shandong, 255049, People’s Republic of China

    Zhiguang Sun, Zenghua Fan, Yebing Tian, Cheng Qian & Zhen Ma

  2. Institute for Advanced Manufacturing, Shandong University of Technology, Zibo, 255049, People’s Republic of China

    Zenghua Fan & Yebing Tian

Authors
  1. Zhiguang Sun
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  2. Zenghua Fan
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  3. Yebing Tian
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  4. Cheng Qian
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Contributions

Zhiguang Sun: writing—original draft, experimentation, investigation. Zenghua Fan: writing-review, methodology, investigation. Yebing Tian: writing-revision and editing, conceptualization, methodology, project administration, funding acquisition, supervision. Cheng Qian: investigation. Zhen Ma: investigation.

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Correspondence to Yebing Tian.

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Sun, Z., Fan, Z., Tian, Y. et al. Investigation on magnetorheological shear thickening finishing (MSTF) with radially slotted magnetic pole for free-form surface. Int J Adv Manuf Technol 123, 3313–3327 (2022). https://doi.org/10.1007/s00170-022-10313-0

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