In this article, an attempt is made to prepare an ice-bonded abrasive polishing (IBAP) tool, in situ, for ultrafine finishing of flat, Electrolytic Copper (EC)-grade copper specimen. Two different methods such as direct and layer-by-layer methods of freezing slurry were tried for preparation of the IBAP tool. Tools prepared by both these methods were characterized to analyze the distribution of abrasives in ice matrix. Polishing experiments were conducted on copper specimen by varying the rotational speed of tool, concentration of silicon carbide abrasives in slurry, contact pressure between tool and work surface, each at two levels. By analyzing the polished surfaces with an optical profilometer and scanning electron microscope, the mechanisms of material removal and surface generation processes are understood. Copyright © Taylor & Francis Group, LLC.

N. Ramesh Babu

Department of Mechanical Engineering

ABRASIVE POLISHING

Contact pressures

COPPER MATERIALS

Experimental investigations

In-situ

LAYER-BY-LAYER METHODS

Material removal

matrix

Optical profilometer

POLISHED SURFACES

Rotational speed

Scanning Electron Microscope

SURFACE GENERATIONS

Ultrafine

UNCONVENTIONAL

Abrasives

Copper

Polishing

Scanning electron microscopy

Silicon carbide

Surfaces

IIT Madras is a public technical and research university located in Chennai, Tamil Nadu. Founded in 1959, it is recognised as an Institute of National Importance.

IIT Madras has been ranked as the top engineering institute in India for four years in a row by the National Institutional Ranking Framework of the MHRD

It currently offers undergraduate, postgraduate and research degrees across 16 disciplines in Engineering, Sciences, Humanities and Management. About 596 faculty belonging to science and engineering departments and centres of the Institute are engaged in teaching, research and industrial consultancy.

IIT Madras

Experimental Investigations on Ice Bonded Abrasive Polishing of Copper Materials

Materials and Manufacturing Processes

This article covers the efforts on characterising ice-bonded abrasive polishing tool in terms of the mechanical and tribological properties such as hardness, coefficient of friction, and wear rate. These studies were attempted on the tools prepared at different temperatures ranging from −10 °C to 0 °C with a view to identify the condition suitable to prepare ice-bonded abrasive polishing tool for effective polishing of Ti–6Al–4V alloy specimen. It also presents the methods adopted to determine various properties of ice-bonded abrasive polishing tool. Hardness was estimated from the measured penetration depth of cone shape indenter into the tool, coefficient of friction was determined from the change in power drawn by the motor rotating the tool mould, and wear behaviour of tool was assessed from the melting rate of the tool determined from the change in height of ice-bonded abrasive polishing tool at different stages of polishing. From the results of this study, it is clear that ice-bonded abrasive polishing tool prepared at −4 °C has possessed sufficient hardness, coefficient of friction, and reasonable wear rate suitable for polishing of Ti–6Al–4V specimens. This article also covers the details of low-temperature coolant supply unit developed to prepare the ice-bonded abrasive polishing tool at any desired temperature between 0 °C and −40 °C and thus to maintain it for a long time. Polishing studies with such ice-bonded abrasive polishing tool showed 72% improvement in finish after 90 min of polishing of Ti–6Al–4V specimen with tool, prepared at −4 °C. © IMechE 2017.

Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture

Mechanical and tribological properties of ice-bonded abrasive polishing tools

This paper covers the development of a multilayer icebonded abrasive polishing (IBAP) tool for multistage polishing of Ti-6Al-4V alloy specimens based on a systematic study that determined the number of layers, thickness of each layer, and the type, size and concentration of abrasives in each layer. Based on this study, a three-layered IBAP tool with the bottom layer consisting of soft aluminum oxide abrasives of 3 µm size with 5% concentration, the middle layer with moderately hard silicon carbide abrasives of 8 µm size with 10% concentration and the top layer with hard boron carbide abrasives of 15 µm size with 30% concentration was formulated for ultrafine finishing of Ti-6Al-4V alloy specimen in a single setup. The performance of the three-layered IBAP tool assessed in terms of finish and morphology over the work surface showed 81% improvement in surface finish, showing its effectiveness over a single-layered IBAP tool. Polishing studies have clearly demonstrated the generation of ultrafine surfaces, yielding a finish of 37 nm while the morphological studies on the polished surface have shown a nearly scratch-free surface on the Ti-6Al-4V alloy. © 2017 Taylor & Francis.

Empirical approach to develop a multilayer icebonded abrasive polishing tool for ultrafine finishing of Ti-6Al-4V alloy

In this article, a novel ice bonded abrasive polishing (IBAP) process proposed for producing ultrafine surfaces on metallic surfaces is presented. An IBAP setup was developed for conducting the experiments under cryogenic conditions. The novelty of the process lies in the method of preparing cryogenic polishing tool by freezing the mixture of distilled water and ultrafine abrasive particles with suitable cryogenic fluids. Characterization of tool, by weight balance method, ensured uniform distribution of abrasives throughout the ice matrix. Experiments were conducted on 304L stainless steel and EC grade copper materials in order to examine the improvements in finish on polished surfaces. Experimental studies have revealed the generation of ultrafine surfaces, yielding roughness values in nanometric range, with the adhesive action of ice and abrasive action of material by fine abrasive particles. Copyright © Taylor & Francis Group, LLC.

Ultrafine finishing of metallic surfaces with the ice bonded abrasive polishing process

This paper presents the efforts made in the design, development and characterisation of a novel method of ice bonded abrasive polishing process. Mechanisms in various types of polishing machines were studied to identify the suitable configuration for developing an ice bonded abrasive polishing setup. Initially, a setup was developed with suitable kinematics for ice bonded abrasive polishing of flat surfaces. With the experience gained with the setup, suitable modifications in the setup were made to build a new setup for effective polishing of flat metallic surfaces. The developed setup is designed to prepare the polishing tool in situ with suitable temperature controller. The novelty of polishing setup lies in the method of preparation of cryogenic polishing tool by freezing the mixture of ultrafine abrasive particles with suitable cryogenic fluids. The characterisation of tool with optical image analysis and weight balance method showed the uniform distribution of abrasives in ice matrix. Finally, the effectiveness of ice bonded abrasive polishing process was demonstrated by analysing the finish produced on flat copper specimen. © 2011 Inderscience Enterprises Ltd.

International Journal of Abrasive Technology

Design, development and characterisation of ice bonded abrasive polishing process

Proceedings of the 36th International MATADOR Conference

Ultra-fine Finishing of Metallic surfaces with Ice Bonded Abrasive Polishing Process

Precision Engineering

Copper polishing with a polishing pad incorporating abrasive grains and a chelating resin

Linear Grinding of Microbores Using Diamond-Adhered Wire

Finishing of structured surfaces by abrasive polishing

Magnetorheological Finishing of SiC Aspheric Mirrors

Experimental investigations on ice bonded abrasive polishing of copper materials

Journal	Materials and Manufacturing Processes
ISSN	10426914
Open Access	No