Mirror-Surface Finishing by Integrating Magnetic-Polishing Technology with a Compact Machine Tool
Yuki Manabe*,, Hiroki Murakami*, Toshiki Hirogaki*, Eiichi Aoyama*, and Tatsuya Furuki**
*Graduate School of Science and Engineering, Doshisha University
1-3 Tataramiyakodani, Kyotanabe-shi, Kyoto 610-0394, Japan
**Graduate School of Engineering, Gifu University, Gifu, Japan
In recent years, owing to the advent of mobile phones, product miniaturization and multifunctionalization have rapidly progressed. However, the large-sized machine tools for the manufacture of small products waste a considerable amount of space and power. The present study aimed at applying a magnetic-polishing method using a ball-end mill-type tool to examine the optimum processing conditions. This was done to apply a mirror finish for the integration of the cutting and polishing processes by using the small machine tool. The magnetic-polishing effect was evaluated from the point of view of the polishing amount, surface roughness, specimen shape, and mirror-surface condition. In addition, the movement of the paste during polishing was observed through images obtained through a high-speed camera. The movement of the paste is considered for effective polishing and other cases. Accordingly, various magnetic-polishing techniques were used for irregularities and step shapes. Various conditions were also examined, and a stable condition was determined. The results reveal that the amount of polishing paste significantly influences the polishing movement. In addition, a sufficient polishing effect could be obtained by duplicating the polishing course by using a sine wave course.
-  S. Okoma, “A history of computer development,” Kyoritsu Shuppan, 2005 (in Japanese).
-  M. Sakagami, “Latest Trends in Foreign Injection Molding Machines and Technologies (Part 1) Accelerating Eco-Molding,” Pursuing Efficiency, and Improving Productivity Through Process Integration, Plastics age, Vol.61, No.10, pp. 90-95, 2015 (in Japanese).
-  R. Neugebauer, M. Wabner, H. Rentzsch, and S. Ihlenfeldt, “Structure principles of energy efficient machine tools,” CIRP J. of Manufacturing Science and Technology, Vol.4, Issue 2, pp. 136-147, 2011.
-  Y. Okazaki, T. Mori, and N. Morita, “Desk-top NC milling machinewith 200 krpm spindle,” Proc. 2001 ASPE Annual Meeting, pp. 192-195, 2001.
-  M. Honiden, “A study of production optimization by cell production system for assembly,” Japan Society for Production Management, Vol.10, No.2, pp. 181-186, 2004 (in Japanese).
-  T. Hirogaki, E. Aoyama, K. Ogawa, T. Niiyama, M. Suzuki, and M. Iwama, “Estimation of environmental impact on desktop size five-axis control machine tools by LCA,” Trans. of the Japan Society of Mechanical Engineers, Series C, Vol.75, No.52, pp. 371-378, 2009 (in Japanese).
-  T. Hirogaki, E. Aoyama, K. Ogawa, and T. Niiyama, “Environmental Impact of Desktop-Sized Five-Axis CNC Machine Tool Estimated with LCA,” Trans. of the JSME, J. of Environment and Engineering, Vol.6, No.2, pp. 242-252, 2011.
-  L. Ma, T. Furuki, T. Kure, T. Hirogaki, and E. Aoyama, “Development of Polishing Tool Capable of Self-Adaptive to Processing Site using Steel Balls and Magnetic Force,” Advanced Materials Research, Vol.806, pp. 466-471, 2015.
-  L. Ma, T. Furuki, W. Wu, T. Hirogaki, and E. Aoyama, “Elucidation of the polishing mechanism by the magnetic polishing brush,” Trans. of the JSME, 2016 (in Japanese).
-  W. Wu, L. Ma, W. Wu, T. Hirogaki, E. Aoyama, M. Ikegaya, T. Echizenya, and S. Hirayoshi, “Study on Oil Adsorption and Polishing Characteristics by Novel Nanofiber Pad for Ultra-Precision Abrasive Machining,” Int. Manufacturing Science and Engineering Conf., 2017, V001T02A043, 2017.
-  H. Murakami, T. Furuki, E. Aoyama, T. Hirogaki, and K. Ogawa, “A33 Consideration about the Magnetic Polishing by End Mill shaped Tool at the Bottom of Micro Channel,” The Japan Society of Mechanical Engineers, Vol.10, pp. 49-50, 2014 (in Japanese).
-  M. Anzai, T. Nakagawa, N. Yoshioka, and S. Banno, “Development of Inline Micro-Deburring Applying Magnetic-Field-Assisted Polishing,” Int. J. Automation Technol., Vol.4, No.1, pp. 9-14, 2010.
-  K. Takahashi, “Deburring Finishing Using a Magnetic Polishing Machine,” Int. J. Automation Technol., Vol.4, No.1, pp. 33-37, 2010.
-  E. Aoyama, T. Hirogaki, K. Ookubo, K. Ogawa, K. Sawa, S. Ogawa, and R. Kawai, “Surface generation for Makyoh magic-mirror by end-milling with digitally functioned CNC machining center and magnetic polishing,” J. of the Japan society for Abrasive Technology, Vol.55, No.9, pp. 540-545, 2011 (in Japanese).
-  Y. Takebayashi, T. Hirogaki, E. Aoyama, K. Ogawa, and S. Melkote, “Application of Magnetic Polishing With Ball Nose Shaped Tool for Microchannel Shape,” ASME J. of Micro and Nano-Manufacturing, Vol.2, No.2, 021009-1-9, 2014.
-  F. W. Preston, “The Theory and Design of Plate Glass Polishing Machine,” J. of Glass Technology, Vol.11, No.44, pp. 214-256, 1927.
-  N. Yasunaga, “Polishing for the first time,” Tokyo Denki University, pp. 84-85, 2011 (in Japanese).
-  T. Nakajo, K. Nakano, and Y. Sawachika, “Measurement for micro shape by reflected light displacement,” Report of the Tokyo Metropolitan Industrial Technic Institute, Vol.27, 4434477, 1995 (in Japanese).
-  M. Hirono and K. Tsunoda, “Turning surface glossiness of aluminum alloys,” The Japan Institute of Light Metals, Vol.35, No.10, pp. 581-587, 1985 (in Japanese).
-  H. Nakagawa, T. Hirogaki, Y. Iwasaki, T. Hayashi, Y. Kita, and Y. Kakino, “Study on oscillation grinding by numerical control with a machining center,” J. of the Japan Society for Precision Engineering, Vol.68, No.7, pp. 923-927, 2011 (in Japanese).
This article is published under a Creative Commons Attribution-NoDerivatives 4.0 Internationa License.