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Experimental and simulation study of magnetorheological miniature gear-profile polishing (MRMGPP) method using flow restrictor

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Abstract

In this article, a new flow restrictor is utilized in the magnetorheological miniature gear-profile polishing (MRMGPP) method to ensure a consistent and precise polishing of gear profiles. The effectiveness of flow restrictor is analyzed using a finite element-based software COMSOL® Multiphysics, where shear stress and axial velocity distributions are studied along gear profiles. Later, the experiments are performed without and with using a novel flow restrictor on the SS316L miniature gear teeth profile to examine the finishing performance and results are compared with each other. After finishing the gear, the minimum surface roughness of 24.1 nm at involute profile is achieved, and also all manufacturing defects are completely removed. Concurrently, the teeth geometry profiles are not affected. The uniform finishing of miniature gear with a continuous smooth surface may improve its work performance, transmitting power ability, reliability, fatigue life and form accuracy.

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Abbreviations

A:

Magnetic vector potential (Tm or Wb/m)

B:

Magnetic flux density (T) or (Wb/m2)

Brem :

Remnant magnetic flux (A/m)

H:

Magnetic field strength (A/m)

m:

Consistency index

M:

Iron particles magnetization (A-m2/Kg)

Mm:

Mass magnetization (emu/g)

Mmrpf :

Magnetization of MRPF particles (A/m)

Ms :

Saturation magnetization (A/m)

P:

Hydarualic pressure (N/m2)

Ux :

Axial velocity component of MRP media (m/s)

Uy :

Radial velocity component of MRP media (m/s)

V:

Volume fraction of each element of MRP media

μ0 :

Relative permeability of free space (Wb/A.m)

ρMRP :

Density of MRP media (g/cm3)

ρ:

Density of each element of MRP media (g/cm3)

T y :

Avg. MRP fluid shear yield stress (Pa)

T :

Shear stress (Pa)

φ:

Volume fraction of IPs

η:

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

χ:

Magnetic susceptibility of IPs (m3/kg)

μr :

Relative permeability of the permanent magnet

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Acknowledgments

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 Implants 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, Guwahati, Assam, 781039, India

    Manjesh Kumar & Manas Das

  2. Department of Mechanical Engineering, National Institute of Technology Patna, Patna, Bihar, 800005, India

    Anupam Alok

Authors
  1. Manjesh Kumar
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  2. Anupam Alok
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  3. Manas Das
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Corresponding author

Correspondence to Anupam Alok.

Additional information

Manjesh Kumar is a Ph.D. Scholar in Indian Institute of Technology Guwahati, India. His research interest focuses on advanced nano-finishing processes, magnetorheological finishing (MRF) process and abrasive flow finishing processes.

Anupam Alok is an Assistant Professor in National Institute of Technology Patna, India. His main research interests include machining, coating, advanced nano-finishing processes, magnetor-heological finishing (MRF) process, advanced/non-traditional machining processes and tribology.

Manas Das is an Associate Professor in Indian Institute of Technology Guwahati, India. His main research interests include advanced finishing and nano-finishing processes, magnetorheological finishing (MRF) process, electropolishing process, micromachining process and tribology.

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Kumar, M., Alok, A. & Das, M. Experimental and simulation study of magnetorheological miniature gear-profile polishing (MRMGPP) method using flow restrictor. J Mech Sci Technol 35, 5151–5159 (2021). https://doi.org/10.1007/s12206-021-1032-z

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  • DOI: https://doi.org/10.1007/s12206-021-1032-z

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