Analysis of Surface Finish Improvement during Ultrasonic Assisted Magnetic Abrasive Finishing on Chemically treated Tungsten Substrate

Abstract

In the era of globalization, the demand of new products with advanced material and process technologies is increasing. Conventional manufacturing techniques are not capable to process the advanced engineering materials with stringent properties. This paper presents a novel approach to finish some advanced engineering materials with stringent properties, which is a challenge for existing conventional machining processes. In this study the positive outcomes of Magnetic Abrasive Finishing (MAF), Chemical-Mechanical Polishing (CMP), and ultrasonic vibrations have been integrated and a novel finishing process Chemo Ultrasonic Assisted Magnetic Abrasive Finishing (CUMAF) has been developed. The machining performance has been enhanced with the process resulting in better surface finish and reduced finishing time. In order to establish the process, an experimental study was done to analyze the influence of five different process variables on surface roughness of workpiece. The response surface methodology and analysis of variance was used to design the experiments and analyze the results respectively. A regression model was also developed and validated, to foresee the process response. Optimization of the model was carried out at the end to obtain the best performance.