Development of a New Internal Finishing of Tube by Magnetic Abrasive Finishing Process Combined with Electrochemical Machining
International Journal of Mechanical Engineering and Applications
Volume 3, Issue 2, April 2015, Pages: 22-29
Received: Apr. 15, 2015;
Accepted: Apr. 29, 2015;
Published: May 16, 2015
Views 5031 Downloads 248
Muhamad Mohd Ridha, Graduate School of Engineering, Utsunomiya University, Utsunomiya-shi, Tochigi-ken, Japan
Zou Yanhua, Graduate School of Engineering, Utsunomiya University, Utsunomiya-shi, Tochigi-ken, Japan
Sugiyama Hitoshi, Graduate School of Engineering, Utsunomiya University, Utsunomiya-shi, Tochigi-ken, Japan
The research proposes a new internal surface magnetic abrasive finishing (MAF) process, which compounded with electrochemical machining (ECM) to decrease machining time. The electrochemical process changes the morphology of the aluminum tube internal surface, producing an oxidation film. Then, we removed the film by magnetic abrasive finishing, results in minimized surface roughness in a significantly reduced processing time when compared to the conventional MAF. In this research, a new experimental set up with a tool that capable of magnetic abrasive finishing and electrochemical finishing was designed and developed to study the machining feasibility. The newly developed finishing method demonstrated simultaneous process of aluminum oxide film formation by ECM and its removal by MAF. This process plays a significant role in preventing the deepening of the pit during ECM and speed up the planarization. The method was developed step by step; firstly, ECM and MAF were conducted in two separate processes. In the second experiment, we modified the finishing conditions to facilitate one-stage finishing method. An investigation of the finishing surface is focusing on the pit size that formed by ECM. The pit size indicated the residue of oxide film because it is a part of the oxidation film construction. Pits morphology changes were observed for certain finishing time to determine the minimum finishing time for its removal. Surface roughness and SEM photograph of the finishing surface were recorded and studied.
Muhamad Mohd Ridha,
Development of a New Internal Finishing of Tube by Magnetic Abrasive Finishing Process Combined with Electrochemical Machining, International Journal of Mechanical Engineering and Applications.
Vol. 3, No. 2,
2015, pp. 22-29.
J. Fisher, E. Kaufmann, and A. Pense, “Effect of Corrosion on Crack Development and Fatigue Life,” Transp. Res. Rec., vol. 1624, no. 98, pp. 110–117, 1998.
C. G. Kumar and S. K. Anand, “Significance of microbial biofilms in food industry : a review,” vol. 42, pp. 9–27, 1998.
H. Yamaguchi and T. Shinmura, “Study of the surface modification resulting from an internal magnetic abrasive finishing process,” Wear, vol. 225–229, pp. 246–255, Apr. 1999.
H. Yamaguchi and T. Shinmura, “Study of an internal magnetic abrasive finishing using a pole rotation system. Discussion of the characteristic abrasive behavior,” Precis. Eng., vol. 24, pp. 237–244, 2000.
Y. H. Zou and T. Shinmura, “Study on Internal Magnetic Field Assisted Finishing Process Using a Magnetic Machining Jig,” in Key Engineering Materials, 2005, vol. 291–292, pp. 281–286.
Y. H. Zou and T. Shinmura, “Development of ultra-precision magnetic abrasive finishing process,” JSME Annu. Meet., vol. 2009, no. 2, pp. 157–158, 2009.
Y. H. Zou, J. N. Liu, and T. Shinmura, “Study on Internal Magnetic Field Assisted Finishing Process Using a Magnetic Machining Jig for Thick Non-Ferromagnetic Tube,” in Advanced Materials Research, 2011, vol. 325, pp. 530–535.
Y. Zou and T. Shinmura, “Development of Magnetic Field Assisted Machining Process Using Magnetic Machining Jig,” Trans. Japan Soc. Mech. Eng. Ser. C, vol. 68, no. 669, pp. 1575–1581, Feb. 2002.
M. R. Muhamad and Y. H. Zou, “A study of electrolytic combined magnetic abrasive finishing for pipe internal surface,” in Japan Society for Precision Engineering Spring Meeting 2014, 2014, pp. 693–694.
S. Lee, Y. Chen, C. P. Liu, and T. J. Fan, “Electrochemical Mechanical Polishing of Flexible Stainless Steel Substrate for Thin-Film Solar Cells,” vol. 8, pp. 6878–6888, 2013.
B.-H. Yan, G.-W. Chang, T.-J. Cheng, and R.-T. Hsu, “Electrolytic magnetic abrasive finishing,” Int. J. Mach. Tools Manuf., vol. 43, no. 13, pp. 1355–1366, Oct. 2003.
K. Okubo and H. Ito, “Electropolishing for Aluminum by Periodic Reversing Current,” J. Surf. Finish. Soc. Japan, 1986.
T. Sasaki and M. Mushiro, “Influence of Electropolishing Conditions on the Occurrence of Irregular Patterns on the Surface of Anodized Aluminum,” 2005.
K. Tajiri and K. Tsujimoto, “Electrolytic Polishing Method of Aluminum for Non-Pitting,” Kinki Res. Surf. Treat. Alum., 1997.
T. Nakayama, “Vibrating electropolishing process of aluminium alloys in phosphoric acid solution (8th Report),” J. Japan Inst. Light Met., vol. 9, pp. 56–66, 1959.
T. a. El-Taweel, “Modelling and analysis of hybrid electrochemical turning-magnetic abrasive finishing of 6061 Al/Al2O3 composite,” Int. J. Adv. Manuf. Technol., vol. 37, pp. 705–714, 2008.
G. Y. Liu, Z. N. Guo, S. Z. Jiang, N. S. Qu, and Y. B. Li, “A study of processing Al 6061 with electrochemical magnetic abrasive finishing,” vol. 14, pp. 234–238, 2014.
Y. W. Jung, J. S. Byun, D. H. Woo, and Y. D. Kim, “Ellipsometric analysis of porous anodized aluminum oxide films,” Thin Solid Films, vol. 517, no. 13, pp. 3726–3730, May 2009.
Y. Kimoto, A. Yano, T. Sugita, T. Kurobe, and M. Yamamoto, Application of micromachining, 5th ed. Tokyo, Japan, 2010.
P. G. Miney, P. E. Colavita, M. V. Schiza, R. J. Priore, F. G. Haibach, and M. L. Myrick, “Growth and Characterization of a Porous Aluminum Oxide Film Formed on an Electrically Insulating Support,” Electrochem. Solid-State Lett., vol. 6, no. 10, p. B42, 2003.