Article
Automation & Control Systems
Zhengyan Zhang, Kang Geng, Guochao Qiao, Jianhua Zhang
Summary: This paper proposes a laser-assisted magnetorheological polishing technology, which successfully reduces shear stress in the polishing zone by establishing a temperature distribution model and experimentally obtaining the relationship between viscosity and temperature.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Manufacturing
Mohsen Derakhshan-Samani, Abdolreza Rahimi
Summary: This research presents an improved design of the BEMRF tool for polishing borosilicate glass lenses. Through simulation and experimentation, it was found that the optimized fluid composition achieved a 59% improvement in surface roughness.
MATERIALS AND MANUFACTURING PROCESSES
(2023)
Article
Engineering, Mechanical
Zili Zhang, Chi Fai Cheung, Chunjin Wang, Jiang Guo
Summary: Fluid jet polishing (FJP) is widely used in precision molding and optical components, but the understanding of surface morphology evolution on the micro scale is incomplete. This paper develops a physical model combining computational fluid dynamics (CFD) simulation and kinetic analysis to predict surface morphology and roughness after FJP. Different parameters are considered in the model and a series of polishing experiments are conducted to validate it.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Article
Engineering, Manufacturing
Vikas Kumar, Rajesh Kumar, Harmesh Kumar
Summary: A novel form of magnetorheological abrasive finishing (MRAF) system has been designed to nano-finish the exterior cylindrical surfaces of various diameters. The optimal combination of finishing parameters has been determined using statistical analysis to achieve high-quality surfaces, demonstrating the superior capabilities of the developed MRAF process.
MATERIALS AND MANUFACTURING PROCESSES
(2023)
Article
Optics
Qiang Liu, Zhiwei Dong, Zhen Chen, Yang Shen, Qiang Li, Peng An
Summary: This paper proposes a flow-focusing-assisted magnetorheological jet polishing method and studies the effects of parameters in the flow-focusing technique on the jet stability through computational fluid dynamics simulation and experiment.
Review
Engineering, Manufacturing
Atul Singh Rajput, Manas Das, Sajan Kapil
Summary: This article explores the evolution, development, applications, process parameters, composition, and analytical models of MR fluid-assisted finishing processes. The key capabilities and limitations of different MR fluid-assisted finishing processes are discussed and compared, providing an overview.
MACHINING SCIENCE AND TECHNOLOGY
(2022)
Article
Engineering, Mechanical
Manjesh Kumar, Rahul Kumar Bharti, Manas Das
Summary: This study utilized a novel uniform flow restrictor for the nano-finishing of miniature gears, ensuring consistent and precise polishing to improve gear surface quality. Experimental results showed that the new method effectively reduced surface roughness and completely eliminated manufacturing defects.
Article
Chemistry, Multidisciplinary
Lin Zhang, Chunlei Zhang, Wei Fan
Summary: This study reveals the influence of robotic normal positioning error on the MRF removal rate, and presents a force-controlled end-effector for robotic MRF process to enhance stability and efficiency.
APPLIED SCIENCES-BASEL
(2022)
Article
Automation & Control Systems
Zhe Lv, Rongguo Hou, Guoyong Zhao
Summary: The use of magnetorheological (MR) fluid can prevent the instability and spreading out of jet flow outside the focusing tube in abrasive waterjet machining, while an external axial magnetic field can improve erosion footprint and processing performance. Results from experiments on alumina validate the effectiveness of applying magnetic field to enhance jet flow concentration and restrain velocity attenuation.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Multidisciplinary
Yan Gu, Mingshuo Kang, Jieqiong Lin, Ao Liu, Bin Fu, Penghui Wan
Summary: The study introduces a vibration-assisted magnetorheological finishing method to enhance the shearing effects of polishing. Experimental results show that variations in vibration parameters affect surface quality and polishing forces, with higher amplitudes and frequencies leading to better surface quality.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2021)
Article
Engineering, Mechanical
Du Xu, Tete Hu
Summary: This paper presents a magnetorheological-based polishing tool and vibration control method to improve stability and reduce vibration during machining, thereby improving the machining quality. Firstly, a polishing end-effector with MR-based damper and magnetic spring mechanism is designed, and the vibration characteristics are theoretically analyzed. Multi-objective optimization is performed to minimize the maximum frequency response value of the polishing system. Then, a disturbance observer is designed to estimate the nonlinear cutting force, and a vibration controller based on polishing force with gravity compensation is proposed to maintain normal contact force and reduce vibration.
MECHANICAL SYSTEMS AND SIGNAL PROCESSING
(2023)
Article
Automation & Control Systems
Atul Singh Rajput, Ambrish Singh, Sajan Kapil, Manas Das
Summary: A computer numerical controlled magnetorheological fluid assisted finishing process can super-finish metallic surfaces without human intervention. This study investigates different toolpath strategies and finds that the Trochoidal toolpath is the most suitable for the process.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Automation & Control Systems
Zhiqiang Xu, Jun Wang, Qiuliang Wang, Heng Wu, Gaofeng Zhang, Shengqiang Jiang
Summary: The study introduced a new smart material-based abrasive tool named MREPCs, which can remove surface material with high precision and shows great potential for ultra-precision machining of small-sized parts.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Acoustics
Yahya Choopani, Mohammad Reza Razfar, Mohsen Khajehzadeh, Mohammadreza Khosrojerdi
Summary: This study proposes the ultrasonic assisted-rotational magnetorheological abrasive flow finishing (UA-RMRAFF) process as a solution to the challenges of the rotational-magnetorheological abrasive flow finishing (R-MRAFF) process. Experimental results show that the UA-RMRAFF process provides a uniform and fine surface finish, increases material removal, and performs surface modification faster than the R-MRAFF process.
Article
Engineering, Manufacturing
Atul Singh Rajput, Ambrish Singh, Sajan Kapil, Manas Das
Summary: This paper presents a method called magnetorheological fluid assisted finishing (MFAF) for achieving a mirror-like polished surface. By using trochoidal toolpaths, the surface quality can be significantly improved. The impact of different process parameters on the surface quality is analyzed and optimized using experiments and response surface methodology (RSM). The biocompatibility of the polished surface is also investigated.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Review
Engineering, Manufacturing
Ambrish Singh, Seema Negi, Sajan Kapil, K. P. Karunakaran, Manas Das
Summary: Anisotropy and omnidirectionality are the main challenges in the growth of additive manufacturing. Omnidirectionality ensures minimal variations in material and geometric properties of the parts, which can be affected by the spatial orientation of process parameters and vectors in AM systems.
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
(2021)
Article
Materials Science, Multidisciplinary
Chandan Kumar, Manas Das
Summary: Fiber laser welding experiments were conducted on SS316L austenitic stainless steel plates, revealing that beam power and welding speed have significant impact on the welding results, while defocused position has a negligible effect on the fusion zone area.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2021)
Article
Engineering, Manufacturing
Abhinav Kumar, Manas Das
Summary: This paper investigates the fabrication of microtools using electrochemical micromachining, comparing the effects of tool rotation and interelectrode gap on the final product. Different shapes of microtools with good surface finish can be achieved through these techniques.
MATERIALS AND MANUFACTURING PROCESSES
(2021)
Article
Engineering, Manufacturing
Manjesh Kumar, Sarfraz Ahmad, Manas Das
Summary: In this study, a novel uniform flow restrictor was designed and developed for precise finishing of miniature gears using rotational magnetorheological fluid-based process. The impact of critical parameters on performance was analyzed through response surface methodology, resulting in improved surface roughness and texture after finishing. The use of different magnetorheological fluids with and without flow restrictors successfully removed manufacturing defects and achieved ultrafine surface roughness on SS316L miniature spur gears. Simulation of the forces involved in finishing gear profiles and a mathematical model for material removal during finishing were also carried out for a better understanding of the controlling mechanisms.
MATERIALS AND MANUFACTURING PROCESSES
(2022)
Article
Engineering, Mechanical
Manjesh Kumar, Rahul Kumar Bharti, Manas Das
Summary: This study utilized a novel uniform flow restrictor for the nano-finishing of miniature gears, ensuring consistent and precise polishing to improve gear surface quality. Experimental results showed that the new method effectively reduced surface roughness and completely eliminated manufacturing defects.
Article
Engineering, Manufacturing
Manjesh Kumar, Anupam Alok, Vikash Kumar, Manas Das
Summary: Surface quality is crucial for product durability and functionality, with conventional finishing methods often causing defects. Advanced finishing techniques, using or not using magnetic fields, play a key role in processing complex products. The selection of polishing particles is essential for ultra-fine finishing of complex free-form products.
MATERIALS AND MANUFACTURING PROCESSES
(2022)
Article
Engineering, Manufacturing
Manjesh Kumar, Manas Das
Summary: This article presents a method for precisely finishing narrow ridge profiles of poppet valves using the rotational-magnetorheological fluid-based finishing process. The impact of process parameters is determined through statistical analysis and simulation of finishing forces. The results show that the finished poppet valves have a smaller surface roughness and may have a longer service life and improved wear and corrosion resistance.
MATERIALS AND MANUFACTURING PROCESSES
(2022)
Article
Engineering, Multidisciplinary
Anwesa Barman, Manas Das, Vimal Kumar Pathak
Summary: This study investigated the potential of magnetic field assisted finishing (MFAF) in the precise finishing of bio-titanium alloy femoral knee implants at the nanometric level. By using response surface methodology and fuzzy logic model, the study established prediction models and analyzed the impact of parameters on surface roughness. An improved salp swarm algorithm (ISSA) was proposed for further optimizing the final surface roughness, resulting in a significant improvement in surface finish compared to default experimental trials.
INTERNATIONAL JOURNAL OF MODELLING AND SIMULATION
(2022)
Article
Automation & Control Systems
Atul Singh Rajput, Ambrish Singh, Sajan Kapil, Manas Das
Summary: A computer numerical controlled magnetorheological fluid assisted finishing process can super-finish metallic surfaces without human intervention. This study investigates different toolpath strategies and finds that the Trochoidal toolpath is the most suitable for the process.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Mechanical
Manjesh Kumar, Manas Das, Nan Yu
Summary: This article introduces a new flow restrictor for precise polishing of miniature gear profiles in the rotational-magnetorheological process, investigates the effects of key factors on polishing performance using response surface method and simulation in COMSOL® software, aiding in accurately understanding the processing mechanism.
JOURNAL OF THE BRAZILIAN SOCIETY OF MECHANICAL SCIENCES AND ENGINEERING
(2022)
Article
Engineering, Manufacturing
Atul Singh Rajput, Ambrish Singh, Sajan Kapil, Manas Das
Summary: This paper presents a method called magnetorheological fluid assisted finishing (MFAF) for achieving a mirror-like polished surface. By using trochoidal toolpaths, the surface quality can be significantly improved. The impact of different process parameters on the surface quality is analyzed and optimized using experiments and response surface methodology (RSM). The biocompatibility of the polished surface is also investigated.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Engineering, Multidisciplinary
Manjesh Kumar, Manas Das
Summary: This article reports on a novel method for uniformly polishing narrow poppet valve profiles to reduce hydrocarbon emissions in aerospace gas propulsion engines. By using different combinations of magnetorheological polishing (MRP) fluid, precise finishing of Nickel aluminium bronze poppet profiles is achieved, resulting in ultrafine surface roughness.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2022)
Article
Engineering, Mechanical
Atul Singh Rajput, Manas Das, Sajan Kapil
Summary: The sustainability of biomaterials depends on their interaction with substances in the human body, and their surface roughness parameters and mechanical properties play a role in reducing degradation and enhancing lifespan. The Magnetorheological Fluid Assisted Finishing (MFAF) process can improve the quality of biomaterials' surface through nano-level average surface roughness. The wear resistance and corrosion resistance of the biomaterials were tested, and it was found that the MFAF process improved their performance.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(2022)
Article
Materials Science, Multidisciplinary
Hari Narayan Singh Yadav, Alok Kumar Das, Manas Das
Summary: This study focuses on the morphology, shape, and size of NPs in nanotechnology. The production of tungsten carbide nanoparticles and the tool wear rate were investigated under different voltage and duty factors in two different dielectrics, EDM oil and kerosene. The results showed that the generation of NPs and tool wear rate increased with an increase in voltage at a constant duty factor. Using EDM oil generated more NPs and less carbide compared to kerosene.
ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES
(2023)
Article
Multidisciplinary Sciences
Manjesh Kumar, Manas Das
Summary: This study investigates the super-finishing of glass-ceramic workpieces using rotational-magnetorheological glass-ceramic polishing (R-MRGP) process. Two different experimental setups are compared in terms of surface roughness, reflectance characteristics, topographical images, and material removal rate (MRR). Finite element analysis (FEA) is used to analyze the magnetic flux density, axial velocity, and shear stress. The study concludes that R-MRGP is a viable option for ultra-precision polishing of glass-ceramics, achieving excellent surface quality.
ARABIAN JOURNAL FOR SCIENCE AND ENGINEERING
(2022)
