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International Journal of Manufacturing and Production Engineering Original Research

Thermo-Mechanical Behavior and Intelligent Optimization of Contact Temperature During Ultrasonic Vibration-Assisted Single-Pole Magnetic Abrasive Finishing of Zinc Alloy

  1. Devesh Ojha Department of Civil Engineering, Amity University
  2. Rajendra Kumar Srivastava Department of Civil Engineering, Motilal Nehru National Institute of Technology

Abstract

This study proposes a new integration of the experimental analysis, multi-physics finite element modelling (FEM) and machine learning (ML) optimisation of contact temperature (CT) in ultrasonic vibration-assisted single pole magnetic abrasive finishing (UV-SPMAF) of zinc alloy. The three gaps of the research are addressed: (i) The absence of a multi-physics FEM model that can couple electromagnetic, thermal and structural fields for UV-SPMAF of zinc; (ii) No quantified contribution of the ultrasonic frequency and amplitude to CT; and (iii) No ML-driven predictive model for CT in this hybrid process. The L-18 Taguchi orthogonal array was used, which contained six parameters: tool speed (250–1250 RPM), working gap (4–6 mm), feed rate (1.5–5.5 mm/s), pulse on time (1–5 min), ultrasonic frequency (20–40 kHz), and amplitude (5–15 µm). ANOVA revealed that working gap (44.21%) and tool speed (34.33%) were dominant factors, while UV frequency (4.16%) and amplitude (2.84%) are statistically significant (p < 0.05). UV assistance gives a decrease in CT of 6.5–9.1% and an increase in the surface roughness of up to 14.2%. The periodic shear-stress relief occurs under UV vibrations as confirmed by FEM (R² = 0.961, RMSE = 0.31°C). For the prediction of CT, R² = 0.9814 was obtained by ANN. Optimal parameters yield CT = 25.71 ± 0.48°C with 51.72% SR improvement. The resultant surface is found to have uniform micro-strains by SEM and XRD.

Keywords

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