It is a research study which aims to enhance the magnetorheological polishing (MRP) process for titanium alloys through modifications to the excitation device and the liquid carrier wheel. Due to their exceptional material properties, titanium alloys are widely used in aerospace, medical, automotive, and other industries. However, the high hardness and high melting point of titanium alloys pose significant challenges for conventional polishing tools to achieve effective surface material removal. In this study, magnetorheological polishing (MRP) is employed to process the surface of titanium alloys, and a pulsed Halbach array is utilized to strengthen the magnetic field, thereby improving the material removal efficiency of the magnetorheological polishing (MRP) process. During the magnetorheological polishing (MRP) process, the magnet rotor is separated from the liquid carrier wheel containing the magnetorheological fluid, and both components are set to rotate concentrically in opposite directions. This configuration induces great variations in the magnetic field lines within the working space, allowing the magnetic flux to exhibit a broad range of motion trajectories. Consequently, the frictional force between the magnetic flux and the liquid carrier wheel is enhanced, ultimately increase the material removal capability.
The objective of optimizing the magnetorheological polishing (MRP) process for titanium alloys is to elevate their surface quality and enhance the polishing efficiency. A comprehensive analysis is performed to evaluate the effects of various polishing parameters within the pulsed Halbach array magnetic field-assisted MRP framework. Parameters under scrutiny include polishing interval, magnet rotational speed, liquid carrier wheel speed, carbonyl iron powder concentration, and abrasive particle concentration, all of which are assessed for their effects on shear force, pressure, and the roughness of titanium alloy surfaces. It is observed that an increase in the polishing interval leads to a gradual reduction in shear force and pressure applied by the polishing tool, while simultaneously increasing the surface roughness of the workpiece. An escalation in magnet rotational speed results in a gradual decrease in shear force, with pressure experiencing minimal fluctuations. The surface roughness of the workpiece follows a pattern of initial increase, subsequent decrease, and a final increase. Accelerating the liquid carrier wheel speed corresponds with an increase in shear force, with pressure changes remaining negligible. The overall surface roughness of the workpiece decreases, with a minor uptick observed after the optimal surface quality is achieved. An increase in carbonyl iron powder concentration induces a gradual rise in both shear force and pressure applied by the polishing tool, with the workpiece's surface roughness mirroring a trend of initial decrease followed by an increase. A rise in abrasive particle concentration initially boosts shear force, which then declines, while pressure continues to ascend. The trend in surface roughness mirrors that observed with increasing magnet rotational speed. Optimal process parameters are attained with a magnetorheological fluid volume of 3 mL, a polishing interval of 0.3 mm, a liquid carrier wheel speed of 250 r/min, a magnet rotational speed of 150 r/min, a carbonyl iron powder concentration of 45wt.%, an abrasive particle concentration of 2wt.%, and a polishing duration of 30 min. Under these conditions, the surface roughness (Sa) of the titanium alloy workpiece is reduced from 60 nm to 36 nm.
The pulsed Halbach array magnetic field-assisted MRP process has been demonstrated to significantly improve the polishing efficiency of magnetorheological fluid and to augment the surface quality of titanium alloy workpieces, positioning it as an effective technique for refining the finish of these materials.
Key words
magnetorheological polishing /
Halbach array /
titanium alloy /
roughness /
pressure and shear forces
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Funding
Major Science and Technology Innovation Project in Wenzhou (ZG2022029); Fundamental Scientific Research Project in Wenzhou (Y20220466); Natural Science Foundation of Zhejiang Province (LQ22E050008); The Master's Innovation Foundation of Wenzhou University (3162024003072)
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