مهندسی ساخت و تولید ایران

مهندسی ساخت و تولید ایران

ارزیابی عملکرد فرایند ماشین‌کاری جریان ساینده به کمک میدان مغناطیسی چرخشی

نوع مقاله : مقاله پژوهشی

نویسندگان
1 گروه مهندسی مکانیک، دانشگاه میبد، میبد، ایران
2 گروه مهندسی مکانیک، دانشگاه صنعتی امیرکبیر، تهران، ایران
10.22034/ijme.2026.573929.2163
چکیده
ماشین‌کاری جریان ساینده (AFM) باوجود کاربرد گسترده در صنایع هوافضا، خودروسازی و پزشکی برای پرداخت‌ سطوح با هندسه پیچیده و غیرقابل‌دسترس، از محدودیت‌هایی مانند زمان پرداخت‌ طولانی و نرخ برداشت ماده پایین رنج می‌برد. در این پژوهش، برای غلبه بر این چالش‌ها، یک فرایند ماشین‌کاری جریان ساینده به کمک میدان مغناطیسی چرخشی (RMF-AFM) ارائه شده است. در این روش، علاوه بر حرکت رفت و برگشتی سیال پولیش‌کاری مگنتورئولوژیکال (MRP) ناشی از فشار اکستروژن، یک میدان مغناطیسی چرخشی ناشی از دوران آهنرباهای دائم بر روی اعمال می‌گردد. عملکرد فرایند پیشنهادی بر روی نسبت زبری سطح، نرخ پرداخت‌کاری و نرخ برداشت ماده لوله‌های آلومینیومی سری 2024 با یک رویکرد تجربی مورد ارزیابی قرار گرفت. مورفولوژی و توپوگرافی سطح نمونه‌ها نیز پیش و پس از پرداخت تحلیل شد. همچنین، یک مطالعه مقایسه‌ای بین کارایی فرایند RMF-AFM و AFM سنتی انجام پذیرفت. یافته‌ها نشان می‌دهد که با افزایش زمان پرداخت‌ از 5 به 10 دقیقه، نسبت زبری سطح از 126/0 به 0192/0کاهش و هم‌زمان نرخ پرداخت‌کاری نیز از 0568/0 به 0933/0 میکرومتر بر دقیقه افزایش می‌یابد؛ بااین‌حال، فراتر از این بازه زمانی، راندمان فرایند افت می‌کند. در مقابل، نرخ برداشت ماده در بازه زمانی 5 تا 15 دقیقه به‌طور پیوسته از 266/1 به 733/2 میلی‌گرم بر دقیقه رشد کرده است. مشاهدات میکروسکوپی ضمن تأیید این نتایج، مؤید آن است که فرایند RMF-AFM اصلاح سطح داخلی لوله‌های آلومینیومی را با سرعت و کیفیت بالاتری محقق می‌سازد. علاوه بر این، نتایج مقایسه‌ای نهایی نیز حاکی از برتری 45/24 درصدی عملکرد فرایند RMF-AFM نسبت به روش AFM سنتی می‌باشد.
کلیدواژه‌ها

عنوان مقاله English

Performance evaluation of rotary magnetic field-assisted abrasive flow machining process

نویسندگان English

Yahya Choopani 1
Mohsen Khajehzadeh 2
Mohammad Reza Razfar 2
1 Department of Mechanical Engineering, Meybod University, Meybod, Iran
2 Mechanical Engineering Department, Amirkabir University of Technology, Tehran, Iran
چکیده English

abrasive flow machining (AFM), despite its widespread application in aerospace, automotive, and medical industries for finishing surfaces with complex and hard-to-reach geometries, suffers from limitations such as long processing times and low material removal rates. To overcome these challenges, this study proposes a rotary magnetic field-assisted abrasive flow machining (RMF-AFM) process. In this method, a rotating magnetic field is applied to a magnetorheological polishing fluid. The performance of the proposed process was experimentally evaluated on 2024 series aluminum alloy tubes in terms of surface roughness ratio, finishing rate, and material removal rate (MRR). The surface morphology and topography of the samples were also analyzed before and after finishing. Furthermore, a comparative study was conducted between the efficiency of the RMF-AFM and conventional AFM processes. The findings indicate that increasing the finishing time from 5 to 10 minutes reduces the surface roughness ratio from 0.126 to 0.0192, while simultaneously increasing the finishing rate from 0.0568 to 0.0933 µm/min. However, beyond this time interval, the process efficiency declines. In contrast, the MRR increased consistently from 1.266 to 2.733 mg/min over the 5 to 15-minute interval. Microscopic observations confirm these quantitative results and demonstrate that the RMF-AFM process achieves internal surface modification of aluminum tubes with higher speed and quality. Additionally, the final comparative results indicate a 24.45% superiority in the performance of the RMF-AFM process compared to the conventional AFM method.

کلیدواژه‌ها English

Abrasive Flow Machining
Rotary Magnetic Field
Surface Roughness Ratio
Finishing Rate
Material Removal Rate
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