The better finish may be desired for looks, accuracy, weaving qualities or for
any other reason. Some materials like glass, ceramics, acrylic resins & plastics are in
herently brittle in nature, so during conventional grinding the cracks may be
formed, which can significantly reduce the strength & reliability of the material in
service.
The abrasive cuts the surface of the workpiece in three phases. The first phase
is when the abrasive first contacts the workpiece surface: dull grains of the abrasive
fracture and fall away leaving a new sharp cutting surface. In the second phase the
abrasive "self dresses" while most of the stock is being removed. Finally, the abrasive
grains become dull as they work which improves the surface geometry.
Types
Through-feed
This type of superfinishing is used for cylindrical workpieces. The workpiece
is rotated between two drive rollers, which also move the machine as well. Four to
eight progressively finer abrasive stones are used to superfinish the workpiece. The
stones contact the workpiece at a 90° angle and are oscillated axially. Examples of
parts that would be produced by process include tapered rolls, piston pins, shock
absorber rods, shafts, and needles.
Plunge
This type is used to finish irregularly shaped surfaces. The workpiece is
rotated while the abrasive plunges onto the desired surface.
Wheels
Abrasive cups or wheels are used to superfinish flat and spherical surfaces.
The wheel and workpiece are rotated in opposite directions, which creates the cross-
hatching. If the two are parallel then the result if a flat finish, but if the wheel is tilted
slightly a convex or concave surface will form.
Abrasives
Common abrasives used for superfinishing include aluminum oxide, silicon
carbide, cubic boron nitride (CBN) and diamond.
The surface finish has a vital role in influencing functional characteristics like
wear resistance, fatigue strength, corrosion resistance.
Lapping
Honing
Superfinishing
Burnishing
CHAPTER 6
Present Processes
Present Processes
LAPPING:-
This can take two forms. The first type of lapping (traditionally
called grinding), involves rubbing a brittle material such as glass against a surface
such as iron or glass itself (also known as the "lap" or grinding tool) with an abrasive
such as aluminum oxide, jeweller's rouge, optician's rouge, emery, silicon
carbide, diamond, etc., between them. This produces microscopic conchoidal
fractures as the abrasive rolls about between the two surfaces and removes material
from both.
In terms of sharpening knives, a honing steel does not actually hone knives,
but simply realigns the metal along the edge.
Honing Stones :-
Honing uses a special tool, called a honing stone or a hone, to achieve a
precision surface. The hone is composed of abrasive grains that are bound together
with an adhesive. Generally, honing grains are irregularly shaped and about 10 to 50
micrometers in diameter (300 to 1,500 mesh grit). Smaller grain sizes produce a
smoother surface on the workpiece.
A honing stone is similar to a grinding wheel in many ways, but honing stones
are usually more friable so that they conform to the shape of the workpiece as they
wear in. To counteract their friability, honing stones may be treated with wax or sulfur
to improve life; wax is usually preferred for environmental reasons
In grinding, the wheel follows a simple path. For example, in plunge grinding
a shaft, the wheel moves in towards the axis of the part, grinds it, and then moves
back out. Since each slice of the wheel repeatedly contacts the same slice of the
workpiece, any inaccuracies in the geometric shape of the grinding wheel will be
transferred onto the part. Therefore, the accuracy of the finished workpiece geometry
is limited to the accuracy of the truing dresser. The accuracy becomes even worse as
the grind wheel wears, so truing must occur periodically to reshape it.
The limitation on geometric accuracy is overcome in honing because the
honing stone follows a complex path. In bore honing for example, the stone moves
along two paths simultaneously. The stones are pressed radially outward to enlarge
the hole while they simultaneously oscillate axially. Due to the oscillation, each slice
of the honing stones touch a large area of the workpiece. Therefore, imperfections in
the honing stone's profile cannot transfer to the bore. Instead, both the bore and the
honing stones conform to the average shape of the honing stones' motion, which in the
case of bore honing is a cylinder. This averaging effect occurs in all honing processes;
both the workpiece and stones erode until they conform to the average shape of the
stones' cutting surface. Since the honing stones tend to erode towards a desired
geometric shape, there is no need to true them. As a result of the averaging effect, the
accuracy of a honed component often exceeds the accuracy of the machine tool that
created it.
The path of the stone is not the only difference between grinding and honing
machines, they also differ in the stiffness of their construction. Honing machines are
much more compliant than grinders. The purpose of grinding is to achieve a tight size
tolerance. To do this, the grinding wheel must be moved to an exact position relative
to the workpiece. Therefore, a grinding machine must be very stiff and its axes must
move with very high precision.
Fig Honing Process
White & grey aluminium oxide abrasives are used on high tensile strength
metals, such as carbon and alloy steel, tough iron, and nonferrous alloys. Gray silicon
carbide abrasives are used on hard and brittle substances, such as grey
iron and cemented carbide, and low tensile strength metals, such as brass, aluminium,
and copper.
Process:-
The condition of the material at hand determines what type of abrasive will be
applied. The first stage, if the material is unfinished, starts with a rough abrasive
(perhaps 60 or 80 grit) and each subsequent stage uses a finer abrasive, such as 120,
180, 220/240, 320, 400 and higher grit abrasives, until the desired finish is achieved.
The rough (i.e. large grit) passes remove imperfections within the metal surface like
pits, nicks, lines and scratches. The finer abrasives leave progressively finer lines that
are not visible to the naked eye. To achieve a #8 Finish (Mirror) it requires polishing
and buffing compounds, polishing wheels and high speed polishing machines or other
machine tools that can be used for polishing, like an electrical drill. Lubricants like
wax and kerosene may be used as lubricating and cooling media during these
operations, although some polishing materials are specifically designed to be used
―dry.‖ Buffing may be done by hand with a stationary polisher or die grinder, or it
may be automated using specialized equipment.
When buffing there are two types of buffing motions: the cut motion and
the color motion. The cut motion is designed to give a uniform, smooth, semi-bright
surface finish. This is achieved by moving the workpiece against the rotation of the
buffing wheel, while using medium to hard pressure. The color motion gives a clean,
bright, shiny surface finish. This is achieved by moving the workpiece with the
rotation of the buffing wheel, while using medium to light pressure.
Burnishing:-
The burnishing process consists of pressing hardened steel rolls or balls into
the surface of the work piece and imparting a feed motion to the same. Ball
burnishing of a cylindrical surface is illustrated
Dragging the ball across the plate will have a different effect than pressing. In
this case, the force on the ball can be decomposed into two component forces: one
normal to the plate's surface, pressing it in, and the other tangential, dragging it along.
As the tangential component is increased, the ball will start to slide along the plate. At
the same time, the normal force will deform both objects, just as with the static
situation. If the normal force is low, the ball will rub against the plate but not
permanently alter its surface.
The rubbing action will create friction and heat, but it will not leave a mark on
the plate. However, as the normal force increases, eventually the stresses in the plate's
surface will exceed its yield strength. When this happens the ball will plow through
the surface and create a trough behind it. The plowing action of the ball is burnishing.
Burnishing also occurs when the ball can rotate, as would happen in the above
scenario if another flat plate was brought down from above to induce downwards
loading, and at the same time to cause rotation and translation of the ball, or in the
case of a ball bearing
The surface finish has a vital role in influencing functional characteristics like
wear resistance, fatigue strength, corrosion resistance.
This method is based on the Ferro hydrodynamics behavior of the magnetic fluid.
CHAPTER 8
Objectives
OBJECTIVES:
5. Taking trials on machine and measure the surface finish of the component.
Ferro fluid is a magnetic fluid made out of nanometre sized pieces of iron or
various iron oxides, suspended in a liquid. The shapes and flow of ferrofluid are
surprising and beautiful, and show how magnetic field lines curve around magnetic
objects.
A ferro fluid is a fluid with magnetic particles in it, and if the fluid is exposed
to a magnetic field, all the magnetic particles will align with the field lines, and
making the fluid much denser.
Fig Ferrofluid
In order to achieve this repulsive mechanism, the particles can either be coated
by a surfactant (surface active material) to produce an entropic repulsion, or the
surface of the particles can be charged thereby producing an electrostatic repulsion.
For dispersions in liquid a metal, stability has not been achieved due to the lack of a
method to produce a repulsive mechanism.
• Acetone: We need separate Ferric oxide from plastic tapes. Acetone will melt binder
and separate Ferric oxide
• Cooking oil: Cooking oil is needed so as to mix it with ferrite particles Fig shows
cooking oil.
Fig Acetone
Fig Vegetable oil
• Magnets:
Magnets are used to produce magnetic field so that when ferro fluid is exposed to
magnetic field, all the magnetic particles will align with the field lines, and making
the fluid denser.
Fig Magnets
PROCEDURE
The procedure to prepare the ferrofluid is as follows:
1. acetone 500ml
Fig Bowl
3) Melt binder and separate Fe2O3:
We need separate Ferric oxide from plastic tapes. Acetone will melt binder and
separate Ferric oxide. Find large enough bowl. Put all tapes in and fill bowl with
acetone. Wait few hours. You should close bowl with something to keep acetone from
vaporizing.
4) Ferric oxide from the plastic tapes is mixed with the cooking oil which makes a
substance that's liquid when it's sitting around, but turn solid in the presence of a
magnetic field as shown in Fig 24.Therefore magnetic fluid is prepared.
This is also an easy and best way of preparing magnetic fluid. The ingredients
required for its preparation are as follows:
• Magnetic (MICR) ink: The ink is a dry magnetic ink that's used to print checks and
other documents that use magnetic character recognition.
• Household oil: Many types of oils can be used, but it seemed like a light lubricating
oil works best, but any cooking oil will work fine, as well. The amount of oil you
have is pretty much the amount of ferrofluid you'll get out-- about 50mL is good for
starters.
Fig Magnetic ink
1 Pour some oil into a mixing cup. Add a bit of the ink, and stir it into the oil.
3) Keep on adding ink and stirring until you have a thick solution
4) A good guideline for identifying a well-mixed fluid is that if you tip your mixing
cup, the fluid should ooze rather than slosh.
Fig Ferrofluid
CHAPTER 10
Working Mechanism
7.WORKING MECHANISM
This method is based on the Ferro hydrodynamics behaviour of the magnetic fluid
which has the ability to float a nonmagnetic abrasive under the influence of the
magnetic field. Magnetic fluids are colloidal dispersions of sub domain ferromagnetic
particles, usually magnetite, in various kinds of carrier liquids. One particular class of
Ferro fluids is made stable against particle agglomeration by the addition of a surface
active agent. When magnetic fluid is placed in magnetic field gradient, it is attracted
towards the higher magnetic field side. If a nonmagnetic substance is immersed in a
magnetic fluid, it is discharged relatively to lower magnetic field side as shown in fig
12. When the magnetic field gradient is set in the gravitational direction the
nonmagnetic material is made float on fluid surface by the action of the magnetic
buoyant force.
2. Workpiece aluminium
material
8.COMPONENTS:-
ABRASIVES
abrasives are used for soft work materials. The grain size of abrasive used is about 4
to 34 microns and is very fine powder. The most commonly used abrasives are silicon
carbide (Sic) and aluminum oxide (A12O3). Silicon carbide is used for rapid stock
removal and aluminum oxide for improved surface finish. In this experiment
aluminum oxide is used as abrasive. Photograph shows the fine white powder of
aluminum oxide (A12O3).The abrasive grains used are non-magnetic.
Fig Abrasive Particles
PERMANENT BAR-MAGNETS
To obtain magnetic field, assembly of permanent magnets are used. In order to obtain
a large buoyant force, large magnetic field gradient as well as large magnetic field is
necessary.
For satisfying such condition, several permanent magnets are placed so that the
magnetic poles of adjacent magnets are opposite. Magnets used are neodymium-iron-
boron magnets or samarium cobalt magnets having magnetic induction of 0.8 to 1.2 T
(Tesla).
It is interesting to note that in the magnetic field of 1.1 Tesla a magnetic induction of
10 A/m is generated. Depending upon the requirement of magnetic field, number of
magnets to be used is decided.
Fig workpiece
MOTOR:-
Fig Motor
AUTOTRANSFORMER:-
Fig Autotransformer
FIXTURE/CHUCK:-
Fig Chuck/Fixture
CHAPTER 11
Assembly
ASSEMBLY:-
The components required for the project are discussed in above points. The
final stage in the setup is to assemble all the components so that it is ready for
experimentation. The assembly is carried out in following steps:-
1. Clamp motor to rigid body with the help of nut and bolt arrangement.
2. Attach fixture to the motor shaft with the help of bolting arrangement.
3. Press fit the beaker filled with magnetic fluid against the wooden arrangement
1. 60 2780
2. 80 2824
3. 100 2890
4. 120 2920
5. 140 2930
Table 5: Observation table:-
1. 15 3.50 2.8
2. 15 2.8 2.2
3. 15 2.2 1.55
CHAPTER 13
Expenditure
EXPENDITURE
(In rupees.)
Frame work
1 900
Motor
2 1500
Beaker
3 400
Vegetable oil
4 200
Magnetic ink
5 90
6 Alen Keys 30
Fixture
7 70
Carbide
9 1000
Permanent magnets
10 300
Total
5290
CHAPTER 14
Conclusion
12. CONCLUSION
With the help of magnetic fluid grinding it is possible to grind aluminum material
which is a nonmagnetic material. This method is also applicable to various
nonmagnetic materials such as ceramics, hard plastics and glass.
The initial roughness before grinding process is carried out was 3.50µm, which
reduced to -1.55µm after process is completed. Therefore the purpose of doing this
project is accomplished
CHAPTER 15
Advantages & Disadvantages of
M.F.G.
10. ADVANTAGES OF M.F.G
Can optimize all the parameters for faster and accurate grinding