Magnetorheological polishing parameters effects on aluminium 6061 surface /
Soffarina Binti Mohd Soffie,
Magnetorheological polishing parameters effects on aluminium 6061 surface / Soffarina Binti Mohd Soffie - xv, 115 pages : illustrations ; 30 cm. + 1 CD-ROM
Faculty of Manufacturing and Mechatronic Engineering Technology
Thesis (Master of Science) -- Universiti Malaysia Pahang – 2023
Includes bibliographical references
Micro-milling of Aluminium 6061 produced burr and asperities that can be removed through a polishing process. However, polishing features including v-groove make conventional polishing challenging. The potential solution is by using the Magnetorheological Polishing technique. Yet, the suitable polishing parameters must be investigated as they might affect the material removal rate and surface roughness property. Some of the problems of polishing the micro metal mold using MRP in previous studies are that the polishing tools are in a concave shape, the ball end tool is not nano- sized, and some of the machines are not suitable to polish metal surfaces due to magnetic field strength. Besides, metal micro mold product is less studied by other researchers due to most of the researcher are focused more on glasses and flat surfaces. Researchers studied more on achieving the lowest surface roughness by focusing on MRP machine setup. Therefore, an innovation of MR polishing machine that is mounted on a CNC machine with four sample slots. This machine able is to save time and able to polish metal micro-mold using MRP. This research proposed to investigate the MRP processing parameters’ effects on material removal rate (MRR), surface roughness reduction ratio, and geometrical precision of polished micro mold surfaces. This research aims to study the effect of magnetorheological polishing processing parameters on the material removal rate (MRR) and surface roughness reduction ratio (SRRR) abrasive added magnetorheological polishing media (MRPF). A magnetorheological polishing rig mounted on a computer numerical control (CNC) table was used to polish samples of aluminum v-grooved surface. The sample surface was machined using a CNC milling machine with constant machining parameters. Box-Behnken design of experiment (DOE) is used to investigate the polishing gap (1 to 3mm), rotational speed (50 to 500rpm), and current of (0.5 to 2.5A) relationship on MRR and SRRR. Surface morphology profile and geometrical precision were measured using confocal microscopy after polishing process. MRR and SRRR were analyzed by measuring weight loss and area change calculation. A low rotational speed of 50rpm produces MRR and SRRR of 23.67mg/min and 5.08mm3s-1 respectively with a polishing gap of 1mm and a current of 2.5A. The maximum MRR was 23.67mg/min where increasing the current led to an increase in magnetic flux density, where the MR fluid ribbon stiffened. Obtaining a minimum SRRR was 2.74mm3s-1 is best to reduce the ratio as it reduces the stiffness of CIP particles and leads to alumina abrasive scattered distribution and low force between the particles. A lower polishing gap increases the magnetic flux density. The machined surface roughness of both flat-surface and valley are 10.56μm and 4.79μm respectively. The roughness is reduced after MR polishing to 1.15μm and 1.38μm for flat-surface and valley respectively. The surface roughness had been reduced significantly for both the valley and flat surface of the aluminum v-groove. MRP machines can be used for other types of material, shapes, and sizes which depend on the desired MRR and SRRR value. Therefore, MRP is the alternative process with the ability to actively control the polishing region provides a potential replacement.
THE0009829 (Local)
Faculty of Manufacturing and Mechatronic Engineering Technology--Dissertations
Universities and colleges--Dissertations
Magnetorheological polishing parameters effects on aluminium 6061 surface / Soffarina Binti Mohd Soffie - xv, 115 pages : illustrations ; 30 cm. + 1 CD-ROM
Faculty of Manufacturing and Mechatronic Engineering Technology
Thesis (Master of Science) -- Universiti Malaysia Pahang – 2023
Includes bibliographical references
Micro-milling of Aluminium 6061 produced burr and asperities that can be removed through a polishing process. However, polishing features including v-groove make conventional polishing challenging. The potential solution is by using the Magnetorheological Polishing technique. Yet, the suitable polishing parameters must be investigated as they might affect the material removal rate and surface roughness property. Some of the problems of polishing the micro metal mold using MRP in previous studies are that the polishing tools are in a concave shape, the ball end tool is not nano- sized, and some of the machines are not suitable to polish metal surfaces due to magnetic field strength. Besides, metal micro mold product is less studied by other researchers due to most of the researcher are focused more on glasses and flat surfaces. Researchers studied more on achieving the lowest surface roughness by focusing on MRP machine setup. Therefore, an innovation of MR polishing machine that is mounted on a CNC machine with four sample slots. This machine able is to save time and able to polish metal micro-mold using MRP. This research proposed to investigate the MRP processing parameters’ effects on material removal rate (MRR), surface roughness reduction ratio, and geometrical precision of polished micro mold surfaces. This research aims to study the effect of magnetorheological polishing processing parameters on the material removal rate (MRR) and surface roughness reduction ratio (SRRR) abrasive added magnetorheological polishing media (MRPF). A magnetorheological polishing rig mounted on a computer numerical control (CNC) table was used to polish samples of aluminum v-grooved surface. The sample surface was machined using a CNC milling machine with constant machining parameters. Box-Behnken design of experiment (DOE) is used to investigate the polishing gap (1 to 3mm), rotational speed (50 to 500rpm), and current of (0.5 to 2.5A) relationship on MRR and SRRR. Surface morphology profile and geometrical precision were measured using confocal microscopy after polishing process. MRR and SRRR were analyzed by measuring weight loss and area change calculation. A low rotational speed of 50rpm produces MRR and SRRR of 23.67mg/min and 5.08mm3s-1 respectively with a polishing gap of 1mm and a current of 2.5A. The maximum MRR was 23.67mg/min where increasing the current led to an increase in magnetic flux density, where the MR fluid ribbon stiffened. Obtaining a minimum SRRR was 2.74mm3s-1 is best to reduce the ratio as it reduces the stiffness of CIP particles and leads to alumina abrasive scattered distribution and low force between the particles. A lower polishing gap increases the magnetic flux density. The machined surface roughness of both flat-surface and valley are 10.56μm and 4.79μm respectively. The roughness is reduced after MR polishing to 1.15μm and 1.38μm for flat-surface and valley respectively. The surface roughness had been reduced significantly for both the valley and flat surface of the aluminum v-groove. MRP machines can be used for other types of material, shapes, and sizes which depend on the desired MRR and SRRR value. Therefore, MRP is the alternative process with the ability to actively control the polishing region provides a potential replacement.
THE0009829 (Local)
Faculty of Manufacturing and Mechatronic Engineering Technology--Dissertations
Universities and colleges--Dissertations