Skip to main content
SpringerLink
Log in

Magnetic-Assistance Finishing Processes in Freeform Surfaces

  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

A new finishing process that uses magnetic force with high efficiency to assist discharging dregs from the electrode gap during electrochemical finishing on freeform surfaces is investigated in the current study. The factors affecting electrochemical finishing and the effects of magnetic assistance are primarily discussed. The main experimental parameters are magnetic strength, distance between the two magnets, diameter of the electrode, current density, the on/off period of pulsed current, and rotational speed of the wire electrode. Providing a large magnetic field intensity or using a smaller distance between the two magnets produces a larger magnetic force and discharge efficiency, and results in a better finish. A higher current density with magnetic assistance reduces the finishing time and avoids difficulties in dreg removal. A high rotational speed of the wire electrode produces a better finish. Pulsed direct current can slightly promote the effect of electrochemical finishing, but the current density needs to be higher. Magnetic assistance during the electrochemical finishing process makes a greater contribution in a shorter time making the surface of the workpiece smooth and bright.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

References

  1. B.H. Amstead, P.F. Ostwald, M.L. Begeman (1977) Ostwald, Manufacturing Processes. John Wiley and Sons, Inc., New York, p 614.

    Google Scholar 

  2. J. Unger, M. Stiemer, B. Svendsen, and H. Blum 2006 Multifield Modeling of Electromagnetic Metal Forming Processes. J. Mater. Process. Technol. 177 (1–3): 270–273.

    Article  CAS  Google Scholar 

  3. M. Badelt, C. Beerwald, A. Brosius, and M. Kleiner, Processes Analysis of Electromagnetic Sheet Metal Forming by On Line-Measurement and Finite Element Simulation, Proceedings of the 6th International ESAFORM Conference on Materials Forming (Salermo, Italy), 2003, p 123–126

  4. V.K. Jain, S.C. Jayswal, and P.M. Dixit 2007 Modeling and Simulation of Surface Roughness in Magnetic Abrasive Finishing Using Non-Uniform Surface Profiles. Mater. Manuf. Process. 22: 256–270.

    Article  CAS  Google Scholar 

  5. G.W. Chang, “Study on Finishing Characteristics of Magnetic Abrasive Finishing and Electrolytic Magnetic Abrasive Finishing,” Doctoral Dissertation, National Central University, Taiwan, 2003

  6. S.C. Jayswal, V.K. Jain, P.M. Dixit 2004 Analysis of Magnetic Abrasive Finishing with Slotted Magnetic Pole. Mater. Process. Des. 712: 1435–1440.

    CAS  Google Scholar 

  7. H.S. Lee, “Machining Characteristics and Optimization of Machining Parameters with Assistant Magnetic Force in EDM,” M.Sc. Thesis, National ChungChou Institute of Technology, Taiwan, 2005

  8. S. Hao, P.M. Kirkham, T.M. Myers, G.H. Cassell, and G.U. Lee 2005 The Application of Magnetic Force Differentiation for the Measurement of the Affinity of Peptide Libraries. J. Magn. Magn. Mater. 293(1), 382–388.

    Article  Google Scholar 

  9. P. Domanowski, J. Kozak, Inverse Problem of Shaping by Electrochemical Generating Machining. J. Mater. Process. Technol. 109, 347–353 2001

    Article  Google Scholar 

  10. J.A. McGeough 1974 Principles of Electrochemical Machining. Chapman & Hall, London, p. 1–10.

    Google Scholar 

  11. J. Wilson 1971 Practice and Theory of Electrochemical Machining. Wiley-Interscience, New York, p. 79–161.

    Google Scholar 

  12. A.R. Mileham, Harrey S.J. and Stout K.J. 1986 The Characterization of Electrochemically Machined Surfaces. Wear 109, 207–214.

    Article  Google Scholar 

  13. W.M. Shen, “The Study of Polishing of Electric Discharge-Machined Mold With ECM,” M.Sc. Thesis, National Yunlin Institute of Technology, Taiwan, 1995

  14. M. Datta and D. Landolt, Electrochemical Machining Under Pulsed Current Conditions, Electrochim. Acta, 1981, 26, p 899–907

    Article  CAS  Google Scholar 

  15. J. Zhou, G. Pang, H. Wang, and W. Xu, Research on Pulse Electrochemical Finishing Using a Moving Cathode, Int. J. Manuf. Technol. Manage., 2005, 7(2–4), p 352–365

    Article  Google Scholar 

  16. L. Cagnon, V. Kirchner, M. Kock, R. Schuster, G. Ertl, W.T. Gmelin, and H. Kuck (2003) Electrochemical Miromachining of Stainless Steel by Ultra Short Voltage Pulses. Z. Phys. Chem. 217, 299–313.

    Article  CAS  Google Scholar 

  17. T. Jones 2004 Electropolishing of Precious Metals. Metal Finish. 102(7–8), 45–49.

    Article  Google Scholar 

  18. V.K. Jain, P.G. Yogindra, S. Murugan 1987 Prediction of Anode Profile in ECBD and ECD Operations. Int. J. Mach. Tools Manuf. 27(1), 113–134.

    Article  CAS  Google Scholar 

  19. H. Hocheng, and P.S. Pa 2003 Electropolishing of Cylindrical Workpiece of Tool Materials Using Disc-Form Electrodes. J. Mater. Process. Technol. 142(1), 203–212.

    Article  CAS  Google Scholar 

  20. P.S. Pa, and H. Hocheng 2006 Using Borer-Shape Electrode in Electrochemical Smoothing of Holes. Mater. Sci. Forum 505–507, 793–798.

    Article  Google Scholar 

  21. T.P. Griego and J.W. Eichman, Electrodeposition Apparatus and Method using Magnetic Assistance and Rotary Cathode for Ferrous and Magnetic Particles, United States Patent 6890412, 2003, p 1–9

  22. L.B. Archer, Systematic Method for Designer, Developments in Design Methodology, N. Cross, Ed., John Wiley, 1984, p 57–82

  23. S.S. Rao, Engineering Optimization, John Wiley and Sons, New York, 1996

  24. G. Pahl and W. Beitz, Engineering Design: A Systematic Approach, K. Wallace, Ed., Springer, Berlin, 1996, p 79–81

  25. Yung Dah Special Steel Co., Ltd., Hitachi, YSS, Cold Work Tool-Steel, Taiwan, 2000, p 2–3

  26. Institute of Advanced Manufacturing Sciences, Inc., Machining Data Handbook, 3rd ed., Vol. 2, Sec. 18, 1980, p 11

Download references

Acknowledgment

The current study is supported by National Science Council, contract 96-2622-E-152-001-CC3 and 96-2411-H-152-003.

Author information

Authors and Affiliations

  1. Graduate School of Toy and Game Design, National Taipei University of Education, No. 134, Sec. 2, Heping E. Rd., Taipei City, 106, Taiwan, ROC

    P.S. Pa

Authors
  1. P.S. Pa
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to P.S. Pa.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Pa, P. Magnetic-Assistance Finishing Processes in Freeform Surfaces. J. of Materi Eng and Perform 18, 399–405 (2009). https://doi.org/10.1007/s11665-008-9308-3

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-008-9308-3

Keywords

Search

Navigation