Experimental Investigation on Magnetic Abrasive Finishing for Internal Surfaces of Waveguides Produced by Selective Laser Melting
Abstract
:1. Introduction
2. Experiment
2.1. Implementation
2.2. Conditions and Method
3. Results and Discussion
3.1. Regression Model
3.2. Separate Impacts of Linear Variables on the Response
3.3. Combined Impacts of Factors on the Response
3.4. Process Optimization
3.5. Comprehensive Evaluation
- (1)
- Surface morphology before processing
- (2)
- Morphology on the cavity bottom after processing
- (3)
- Morphology on the convex surface after processing
- (4)
- Morphology on the side wall after processing
4. Conclusions
- (1)
- Utilizing steel balls as magnetic abrasives for rough processing can facilitate a rapid decrease in internal surface roughness.
- (2)
- When using magnetic abrasive particles as polishing tools, the optimal process parameters include a processing gap of 2 mm, magnetic pole rotation velocity of 650 r/min, vibration frequency of 16 Hz, and MAPs size of 40 mesh.
- (3)
- Following sequential rough and fine processing of the internal cavity of the waveguide, the Ra of the blind cavity bottom, side wall, and convex surface can be reduced to 0.59 μm, 0.61 μm, and 1.9 μm, respectively, effectively improving the surface quality inside the waveguide.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Process Parameters | Levels | ||
---|---|---|---|
−1 | 0 | 1 | |
A: Processing gap [mm] | 2 | 3 | 4 |
B: Magnetic polo speed [r/min] | 400 | 600 | 800 |
C: Vibration frequency [Hz] | 10 | 20 | 30 |
D: MAP size [Mesh] | 40 (20–40) | 60 (40–60) | 80 (60–80) |
Exp. No. | Factors and Their Levels | Ra [μm] | |||
---|---|---|---|---|---|
A [mm] | B [r/min] | C [Hz] | D [Mesh] | ||
1 | 4 | 600 | 10 | 60 | 2.14 |
2 | 2 | 400 | 20 | 60 | 1.61 |
3 | 3 | 800 | 20 | 80 | 1.96 |
4 | 2 | 600 | 20 | 40 | 0.69 |
5 | 3 | 800 | 20 | 40 | 1.6 |
6 | 4 | 400 | 20 | 60 | 2.19 |
7 | 3 | 400 | 20 | 40 | 1.65 |
8 | 4 | 600 | 20 | 40 | 1.8 |
9 | 3 | 600 | 10 | 80 | 1.82 |
10 | 3 | 600 | 20 | 60 | 1.51 |
11 | 3 | 400 | 10 | 60 | 2.15 |
12 | 3 | 600 | 30 | 40 | 1.62 |
13 | 3 | 600 | 20 | 60 | 1.41 |
14 | 2 | 600 | 30 | 60 | 1.5 |
15 | 2 | 600 | 10 | 60 | 0.9 |
16 | 4 | 600 | 20 | 80 | 2.05 |
17 | 3 | 800 | 10 | 60 | 1.42 |
18 | 3 | 600 | 20 | 60 | 1.36 |
19 | 3 | 400 | 20 | 80 | 2.34 |
20 | 3 | 600 | 20 | 60 | 1.36 |
21 | 3 | 400 | 30 | 60 | 2.23 |
22 | 4 | 800 | 20 | 60 | 2.2 |
23 | 3 | 800 | 30 | 60 | 2.42 |
24 | 2 | 600 | 20 | 80 | 1.46 |
25 | 3 | 600 | 30 | 80 | 2.23 |
26 | 4 | 600 | 30 | 60 | 2.09 |
27 | 3 | 600 | 20 | 60 | 1.36 |
28 | 2 | 800 | 20 | 60 | 0.89 |
29 | 3 | 600 | 10 | 40 | 1.65 |
Source | SOS | DF | MS | F-Value | Prob > F |
---|---|---|---|---|---|
Model | 5.620 | 14 | 0.401 | 51.370 | <0.0001 |
A | 2.450 | 1 | 2.450 | 313.35 | <0.0001 |
B | 0.235 | 1 | 0.235 | 30.110 | <0.0001 |
C | 0.337 | 1 | 0.337 | 43.090 | <0.0001 |
D | 0.677 | 1 | 0.677 | 86.640 | <0.0001 |
AB | 0.133 | 1 | 0.133 | 17.052 | 0.001 |
AC | 0.106 | 1 | 0.106 | 13.520 | 0.002 |
AD | 0.068 | 1 | 0.068 | 8.653 | 0.011 |
BC | 0.211 | 1 | 0.211 | 27.085 | <0.0001 |
BD | 0.027 | 1 | 0.027 | 3.485 | 0.083 |
CD | 0.048 | 1 | 0.048 | 6.195 | 0.026 |
A2 | 0.008 | 1 | 0.008 | 1.041 | 0.325 |
B2 | 0.827 | 1 | 0.827 | 105.867 | <0.0001 |
C2 | 0.568 | 1 | 0.568 | 72.663 | <0.0001 |
D2 | 0.115 | 1 | 0.115 | 14.760 | 0.002 |
Residual | 0.109 | 14 | 0.008 | ||
LOF | 0.092 | 10 | 0.009 | 2.17 | 0.236 |
PE | 0.017 | 4 | 0.004 | ||
Sum | 5.730 | 28 | |||
Std. Dev. | R2 | Adjusted R2 | Predicted R2 | Adequacy Precision | |
0.088 | 0.981 | 0.962 | 0.903 | 26.297 |
Type | Factors | Ra (μm) | Error (%) | ||||
---|---|---|---|---|---|---|---|
A (mm) | B (r/min) | C (Hz) | D (Mesh) | Predicted | Experimental | ||
Optimized | 2.02 | 654.78 | 16.26 | 40.53 | 0.6 | 0.65 | 7.7 |
Rounded | 2 | 650 | 16 | 40 |
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Wang, L.; Sun, Y.; Xiao, Z.; Yao, L.; Guo, J.; Kang, S.; Mao, W.; Zuo, D. Experimental Investigation on Magnetic Abrasive Finishing for Internal Surfaces of Waveguides Produced by Selective Laser Melting. Materials 2024, 17, 1523. https://doi.org/10.3390/ma17071523
Wang L, Sun Y, Xiao Z, Yao L, Guo J, Kang S, Mao W, Zuo D. Experimental Investigation on Magnetic Abrasive Finishing for Internal Surfaces of Waveguides Produced by Selective Laser Melting. Materials. 2024; 17(7):1523. https://doi.org/10.3390/ma17071523
Chicago/Turabian StyleWang, Liaoyuan, Yuli Sun, Zhongmin Xiao, Liming Yao, Jiale Guo, Shijie Kang, Weihao Mao, and Dunwen Zuo. 2024. "Experimental Investigation on Magnetic Abrasive Finishing for Internal Surfaces of Waveguides Produced by Selective Laser Melting" Materials 17, no. 7: 1523. https://doi.org/10.3390/ma17071523