Micromachining the Aluminium Tubes Using Abrasive Finishing in Alternating Magnetic Field

This study introduced a method based on magnetic field assisted finishing mechanism for micromachining the inner surfaces of Aluminum tubes. In this approach, using the alternating magnetic field of an AC electromotor, abrasive particles were formed as Magnetic Rods (Magnetic Clusters) and surface micromachining was carried out by the dynamic particular pattern made by an alternating magnetic field. The aim of this process was to improve machining efficiency of Aluminum tubes based on surface roughness and dimensional tolerance. Continuously, the effects of parameters such as tube inner diameter, abrasive particles weight, current frequency and machining time on changes of surface roughness were assessed by DOE technique. Taguchi standard orthogonal method (L9 (34)) was used to analyze the process factors. Moreover, the output results derived from experiments were analyzed by two most widely used analytical techniques including Signal to Noise ratio (S/N) and Analysis of Variance (ANOVA). Finally, by considering the results of analysis and plotted graphs, abrasive particles weight and current frequency were identified as significant factors and the optimum conditions of process including tube inner diameter of 55 mm, abrasive particles weight of 1 g, frequency of 40 Hz and machining time of 60 s were obtained.