This study proposes an electropolishing-assisted MAF process using CNTs-Co composites to improve the surface quality of hard-to-machine materials. This hybrid finishing process combines mechanical surface finishing and electrochemical dissolution, occurring simultaneously. Thus, it leads to higher finishing efficiency and surface roughness improvement compared to conventional individual surface finishing processes.
Figure 1 shows a schematic diagram of an operating mechanism. The main components of the apparatus include an electric magnetic inductor, a BLDC motor, a DC power supply, an electrolyte tank, and a
container. The electric magnetic inductor generates magnetic force and is controlled by the BLDC motor, allowing rotation in both directions. The magnetic flux density in the finishing region varies based on the number of permanent magnets attached to the end of the magnetic inductor. When CNTs-Co composites are supplied in the form of slurry into the working gap between the magnetized tool and the workpiece, the composites align into a chain structure due to the magnetic force. This alignment allows for mechanical surface finishing through the rotation of the tool. The flexible composites makes it suitable for applications on freeform surfaces, patterns, and microchannels, with minimal residual stress. The DC power supply is used for electrochemical material removal, and the electrolyte tank with a filter is employed for electrolyte circulation. Sludge formed by electrochemical dissolution and chips produced in mechanical surface finishing process disrupt electrochemical reactions and restrict electrolyte circulation. Consequently, there is a risk of surface damage due to the intense thermal energy generated by an increased resistance. Therefore, the circulation of the electrolyte during the finishing process significantly affects surface finishing efficiency and surface quality improvement. To address this problem, chips and sludge are discharged from the magnetic field by a pump, while the surrounding electrolyte fills the voids, maintaining a consistent density of CNTs-Co composites within the magnetic field. The surface finishing process takes place within the container that is equipped with the micro finishing device capable of adjusting linear movement along both the x and y axes. These rotational and linear motions improve surface roughness for complex geometries of the workpiece.
Based on the aforementioned operating mechanism, the total energy acting on CTNs-Co composites in this hybrid finishing process is represented as the sum of three main energies: \(\:{W}_{m}\), \(\:\:{W}_{r}\), and \(\:{W}_{e}\), as shown in Eq. (1).
$$\:{W}_{total}={W}_{m}+{W}_{r}+{W}_{e}$$
1
\(\:{W}_{m}\) denotes the energy related to mechanical surface finishing process, where CNTs-Co composites align along the magnetic field lines and maintain tension due to attractive forces. The abrasive pressure and strength on CNTs-Co composites are affected by the magnitude of \(\:{W}_{m}\). As the magnetized tool rotates, the mechanical surface finishing process occurs at the tip of the composites, as depicted in Fig. 2.
\(\:{W}_{r}\) signifies the repulsive energy between CNTs-Co composites. Within the magnetic field, CNTs-Co composites and the electrolyte maintain a consistent density influenced by \(\:{W}_{m}\) and \(\:{W}_{r}\). However, when \(\:{W}_{m}\) exceeds \(\:{W}_{r}\), the quantity of composites increases, resulting in higher density. The large amount of composites within the magnetic field restricts electrolyte circulation. As a result, surface damage can be accelerated due to increased resistance and higher thermal energy.
\(\:{W}_{e}\) play an important role in the electrochemical finishing process. When current is applied to the magnetized tool and workpiece connected to the cathode and anode, respectively, electrons from the tool move toward CNTs-Co composites and the electrolyte, inducing electrochemical dissolution on the workpiece surface. \(\:{W}_{e}\) can be controlled via voltage adjustments, allowing control over the magnitude of electrochemical removal depending on voltage variations. In addition, bubbles generated by electrochemical reactions, as depicted in Fig. 2, cause CNTs-Co composites to float upward due to buoyancy, filling voids with new CNTs-Co composites. This cyclic circulation of abrasive particles eliminates the need for dressing and facilitates to easy discharge of chips and sludge.