Magnetic field assisted abrasive based micro-/nano-finishing
Magnetic field assisted abrasive based micro-/nano-finishing
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DOI：
10.1016/j.jmatprotec.2009.08.015
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发表时间：
2009-11-19
影响因子：
6.3
通讯作者：
Jain, V. K.
中科院分区：
文献类型：
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作者：
Jain, V. K.
微纳加工（简称MINIM）过程主要分为两类：传统和先进。大多数传统的MNM工艺是嵌入式磨料或固定几何形状的切削工具类型的工艺。相反，大多数先进的MNM工艺是基于松散流动磨料的工艺，其中磨料取向及其在与工件相互作用时的几何形状不固定。存在一些不属于基于磨料的MNM类别的MNM工艺，例如激光束加工、电子束加工、离子束加工和质子束加工。本文仅对各种基于流动磨料的MNM工艺进行了全面的综述。它还提出了一个通用的机制，这些过程中的材料去除。本文讨论的MNM加工工艺包括：磨粒流光整加工（AFF）、磁粒流光整加工（MAF）、磁流变光整加工、磁流变磨粒流光整加工、弹性发射加工（EEM）和磁悬浮抛光。EEM通过使用具有精确控制的力的纳米尺寸磨料颗粒而导致亚纳米级的表面光洁度。除了两个（AFF和EEM），上述所有其他过程都使用了一种介质，其性质可以在磁场的帮助下进行外部控制。这允许控制作用在磨料颗粒上的力，因此也控制了去除的材料的量。这类工艺能够产生8nm或更低的表面粗糙度值。使用更好的力控制和更细的磨料颗粒，这些工艺中的一些可能导致成品零件上的亚纳米表面粗糙度值。了解这些过程中磨料的材料去除和旋转机制将有助于合理化一些实验观察，否则似乎与既定的理论相矛盾。这也解释了为什么在MAF中使用的磁体应该有一个槽，即使槽下的区域有“非加工”区。根据实验观察，阐述了磁力搅拌器采用脉冲直流电源代替直流平滑电源的原因。(C)2009爱思唯尔有限公司版权所有。
Micro-nano-machining (abbreviated as MINIM) processes are classified mainly in two classes: traditional and advanced. Majority of the traditional MNM processes are embedded abrasive or fixed geometry cutting tool type processes. Conversely, majority of the advanced MNM processes are loose flowing abrasive based processes in which abrasive orientation and its geometry at the time of interaction with the workpiece is not fixed. There are some MNM processes which do not come under the abrasive based MNM category, for example, laser beam machining, electron beam machining, ion beam machining, and proton beam machining. This paper gives a comprehensive overview of various flowing abrasive based MNM processes only. It also proposes a generalized mechanism of material removal for these processes. The MNM processes discussed in this paper include: Abrasive Flow Finishing (AFF), Magnetic Abrasive Finishing (MAF), Magnetorheological Finishing, Magnetorheological Abrasive Flow Finishing, Elastic Emission Machining (EEM) and Magnetic Float Polishing. EEM results in surface finish of the order of sub-nanometer level by using the nanometer size abrasive particles with the precisely controlled forces. Except two (AFF and EEM), all other processes mentioned above use a medium whose properties can be controlled externally with the help of magnetic field. This permits to control the forces acting on an abrasive particle hence the amount of material removed is also controlled. This class of processes is capable to produce surface roughness value of 8 nm or lower. Using better force control and still finer abrasive particles, some of these processes may result in the sub-nanometer surface roughness value on the finished part. Understanding the mechanism of material removal and rotation of the abrasives in these processes will help in rationalization of some of the experimental observations which otherwise seem to be contradicting with the established theories. It also explains why a magnet used in MAF should have a slot in it even though the area under the slot has "non-machining" zone. It elaborates based on the experimental observations why to use pulse D.C. power supply in MAF in place of smooth D.C. power supply. (C) 2009 Elsevier B.V. All rights reserved.