Gonopol'skiy Nick Faculty of Mechanical Engineering Speciality: Metal-cutting machine tools and systems Research of influence of the modes of MAO on cutting ability of powders with different abrasive constituents Scientific adviser: Polischuk Vladimir

  1 Introduction
  2 Actuality of work
  3 Purpose and tasks of work
  4 Review of existing designs devices for MAM
  5 The design part
  6 The theoretical part

      Magnetic abrasive machining (MAM) is the abrasive treatment which is carried out during the movement of the feedstock and abrasive grains relatively to each other in the magnetic field. The nature of the magnetic abrasive machining consists in the fact that powder ferromagnetic abrasive mass compacted by the magnetic field energy has the abrasive effect onto the work piece. We can successfully machine the cylindrical external and internal surfaces, flat, curved body, spiral ones and others with the magnetic abrasive method. The most widespread application area of the magnetic abrasive machining is the grit decreasing on the machining surfaces with the simultaneous increasing of the qualitative characteristics of the surface layer [1].

      Increasing the accuracy and quality of the surfaces of machines and tools details is one of the priority goals of the mechanical engineering. At present for the achievement of these goals the method of MAM which is one of the new perspective ways of machining and permits to receive inferior surface roughness parameters on the different by physical and mechanical properties materials (steel, hard metals, non-ferrous metals and alloys, glass and the second non-metals) has got wide application. The machine tooling role during MAM is fulfilled by magneto abrasive powders which have high magnetic and cutting properties at the same time. The method of the MAM ensures the procurement of the roughness parameters Ra 0,01 – 1 micrometre, waviness and edging lowering.

      With that, local strength and wear resistance raise and profile bearing length increases. The method has the capability to machine both soft and viscous and non-metal materials. A large number of works in the former Soviet Union and abroad is dedicated to the studying of this method. The researches were directed to both development of the new methods and their realisation organisation, studying the process manufacturing capability and presentation of the process with accompanying data.

      With that, That’s why the topic of this master work is urgent because MAM is one of the contemporary methods of the machining which provides high quality of the treated surface.

      The goal of this work is getting the ball numerical schemes of the magneto abrasive powder and determination of the magnetic abrasive machining process rate influence onto the powders cutting ability with different abrasive ingredients.

      The main objective of this work is getting the dependences which describe MAM rate influence onto the powder cutting ability.

      Following the done researches we plan to get numerical schemes of the magneto abrasive powder and also to analyse the MAM rate influence onto the cutting ability of the powders with different abrasive ingredients. At present in the existing MAP numerical schemes there is no information about the methodology via which one needs to calculate the geometrical proportions of the powder ball model.

      The practical part of the master work supposes the carrying out of the experiment.

1) Measuring the geometrical parameters of the MAP grains.
2) Calculating the MAP geometrical models.
3) Weighting the MAP on the analytical balance.
4) Measuring the geometrical parameters of the MAP cutting part.
5) Researching the influence MAM rates onto the cutting ability of the powders with different abrasive ingredients.

      The idea of the magnetic field energy use for the details machine working belongs to N. Kargalov who offered the method of the pipe inner surface treatment with the abrasive powder which has the ferromagnetic behaviour in 1938.

      A number of patents to the methods and devices for the magnetic abrasive machining with free abrasive powder in the variable magnetic field which cyclically changes the polarity was registered in the USA, France and other countries in 1956 – 1959.

      In 1960-1961 in the USSR two groups of the researchers under the direction of V. Shalnov and V. Verezub offered the methods of the abrasive treatment of the non-magnetic materials flat surfaces in the electromagnet field on the direct current.

      In 1962 G. Shulev offered to treat the external cylindrical surfaces on the details like solids of revolution with the powders which have magnetic and abrasive behaviour in the permanent electromagnet field. The first MAM experimental researches were carried out by V. Verozub, V. Shalnov, E. Konovalov in the USSR in 1960 – 1965.

      General abstract theorems, basic physics and technological features of the technology during the different details machining have got the first description in E. Konovalov’s, G. Shulev’s, A. Shteinberg’s and Y. Baron’s works carried out in 1960 – 1970 and also in L. Minin’s, V. Zhdanovich’s, L. Kozhuro’s, A. Kosobutskiy’s, N. Skvorchevskiy’s, L. Kravchenko’s and N. Homich’s ones in the Physicotechnical institute AN BSSR, in V. Panchenco’s work in Bryansk and in Y.Kochur’s work in Moscow.

      From 1980 the researches in the field of the magnetic abrasive machining started to be carried out in other countries (Japan, Bulgaria).

      In 1990 magnetic abrasive machining is studied by the scientific department staff of NAN Belarus Physicotechnical institute, BNTU, scientific and engineering enterprise “Polimag” (Belarus). Theoretical and practical tasks of the polishing in the magnetic field of the cylindrical and spherical surfaces of the goods working mainly in the cars and machines frictional units were developed and realised. Exploratory researches showed the availability of the magnetic abrasive machining use for the details surfaces preparation before the welding and coating operations.

      One has recently been carrying out the researches on the magnetic abrasive machining of the electronics, optics and laser technology precision details surfaces (OP «Polimag», MATI (USA)).

      During the last decade the magnetic abrasive machining technology has got the development in many countries all over the world. Researches in this field are carried out by scientific staff of different universities and companies [1].

      Analysing the existing MAP models which are offered in the works [4 – 6] it should be noted that they don’t have the information about the methodologies via which one needs to calculate the geometrical proportions of the powder ball model which are used in the MAP models. For the elimination of this defect it is necessary at first to analyse the grain distribution of the iron and abrasive powder of different fractions.

Important note

      During the process of writing, the master’s work hasn’t completed yet. Final completion: December, 2011. The full text of work and materials on the theme could be received from the author or him scientific adviser after the indicated date.