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Controllable preparation of non-uniform tool edges by magnetorheological finishing

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Abstract

The cutting-edge radius plays a crucial role in precision machining. An optimally matched radius to the uncut chip thickness can significantly extend tool life. When the uncut chip thickness varies along the cutting edge, preparing the edge with individual radii at different positions is ideal. A novel non-uniform edge preparation approach based on magnetorheological finishing is proposed in this paper. The flexible abrasive tool formed by the magnetorheological effect is presented to prepare a controllable removal and low-damage cutting edge. In this study, the edge preparation device is designed and built, and the structure of the grinding basin is optimized. The magnetic induction intensity distribution in the grinding basin under the action of the external magnetic field is studied. Considering the influence of the magnetic induction intensity, the viscosity change rule of the magnetorheological fluid under different magnetic field intensities is discussed, and a flow field simulation model with variable viscosity is developed. Based on simulation and experiment, the cutting-edge material removal rate is analyzed, and the Preston coefficient is calculated. The results show that magnetorheological preparation can achieve non-uniform directional quantitative removal of edge materials. This study provides a new approach for preparing non-uniform tool edges, which has a positive significance in producing high-performance tools.

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Funding

The study was funded by the National Natural Science Foundation of China (No.51605414), the Postgraduate Research and Practice Innovation Project of Yancheng Institute of Technology (SJCX21_XZ004, SJCX22_XZ017, SJCX22_XY034), and the Key Laboratory Fund Project of Zhejiang Provincial Key Laboratory for Cutting Tools (ZD202110).

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Authors and Affiliations

  1. College of Mechanical Engineering, Yancheng Institute of Technology, Yancheng, 224051, China

    Xiangyu Guan, Donghai Zhao, Yaxin Yu & Shuquan Song

  2. College of School of Medicine, Chemical and Materials Engineering, Taizhou University, Taizhou, 318000, China

    Yaxin Yu

  3. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics & Astronautics, Nanjing, 210016, China

    Dunwen Zuo

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  1. Xiangyu Guan
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  2. Donghai Zhao
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  4. Dunwen Zuo
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Contributions

Xiangyu Guan: validation, investigation, writing—original draft; Donghai Zhao: investigation, writing—original draft; Yaxin Yu: data curation, software, validation; Dunwen Zuo: conceptualization, supervision; Shuquan Song: conceptualization, methodology, supervision, writing—original draft.

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Correspondence to Shuquan Song.

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Guan, X., Zhao, D., Yu, Y. et al. Controllable preparation of non-uniform tool edges by magnetorheological finishing. Int J Adv Manuf Technol 125, 4119–4131 (2023). https://doi.org/10.1007/s00170-023-11019-7

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  • DOI: https://doi.org/10.1007/s00170-023-11019-7

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