A novel surface magnetorheological finishing of TI-6AL–4 V alloy using non-resonant vibration combined with a halbach array
摘要
A novel surface finishing method for Ti-6Al-4 V alloy has been proposed, utilizing the combination of a Halbach magnetic array and non-resonant vibration in the finishing process. This method has exhibited a superior capability of improving the surface integrity of the material. By applying a reasonably arranged Halbach array, a strong magnetic field with an intensity of up to 493 mT was generated. The magnetic field distribution and its variation in air were clarified through simulation results, while a polishing force model induced by abrasive particles was also developed to provide insight into the cutting trajectories, kinematic characteristics, and mechanism of material removal in the Halbach magnetic array and non-resonant vibration (NVMRF) process. Experiments evaluating the influence exerted by slurry flow rate, vibration parameters, and polishing gap were conducted to investigate their influence on polishing forces and surface quality. The results indicated that both tangential and normal forces were significantly improved with increased abrasive flow rate and vibration parameters. Moreover, a polishing distance of 1 mm yielded outstanding surface finishing performance, with material being removed in a plastic deformation state. After optimizing the processing parameters, the proposed method achieved excellent surface finishing results for Ti-6Al-4 V alloy, reducing surface roughness values from 497.63 nm to 1.28 nm after 90 min of processing. This advancement demonstrates the potential of achieving nanometric-level surface finishes for high-performance applications.