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Evaluation of influencing factors of aluminum alloy free-form surface concave magnetic grinding by RSM method

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Document pages: 14 pages

Abstract: Industrial researchers tried to obtain accurate and high-quality surfaces, which led to the invention of new polishing methods. Magnetic grinding is a new grinding method using magnetic field to control grinding tools. Applications such as die surface are one of the parts that require very high surface smoothness. Usually such parts have free-form surfaces. In this study, the influence of magnetic grinding process parameters on free-form surface of aluminum parts is studied. This method is obtained by combining magnetic grinding technology with numerical control computer (CNC). It is a measurement method to use a simple hemisphere installed in the flat area of the magnet and the spark generated by the magnet in the form of curvedone during testing the experiments. The design of experiments is based on response surface methodology. The gap, the rotational speed of the spindle, and the feed rate are found influential and regression equations governing the process are also determined. The impact of intensity of the magnetic field is obtained using the finite element software of Maxwell. Results show that in concave areas of the surface, generally speaking, the surface roughness decreases to 0.2 μm from its initial 1.3 μm roughness. However, in some points the lowest surface roughness of 0.08 μm was measured.

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