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In industries including aerospace, automotive, and marine, a machined component's surface integrity is essential since it improves the corrosion resistance and fatigue life. Hastelloy C-276 is a superalloy based on nickel that is used in the chemical and petrochemical sectors due to its high hot strength, high heat resistance, and high corrosion resistance. In the present work, modelling and simulation of UAMAF process is done on flat work piece with the help of ANSYS Maxwell 16.0 software. The experimental setup for flat work piece on milling machine is modelled according to the dimensions of the experiment. These models are then simulated in ANSYS Maxwell 16.0. After validating the model, the obtained results of analysis were matched with the experimental output. If it is found that the simulation and experiment results vary within the acceptable range, then simulation models are accepted. [ABSTRACT FROM AUTHOR]

Hastelloy C-276 is a nickel-based superalloy having high hot strength, high thermal and corrosion resistance and has led to its use in the chemical and petrochemical industries. In the present study, the ultrasonic-assisted magnetic abrasive finishing process (UAMAF) was used to finish Hastelloy C-276. In the UAMAF process, an additional attachment of ultrasonic horn was added to MAF that applies axial vibrations to the workpiece with a frequency of (10–30 kHz). In this process, normal force and power consumption were measured at different levels of voltage, abrasive percentage, speed, working gap, and power intensity using response surface methodology. The results of UAMAF were compared to responses of MAF under similar experimental conditions. The force and power consumption were increased by 26.8% and 26.6% respectively for UAMAF process compared to MAF process. However, the finishing time was reduced by 60% increasing the production rate. Furthermore, the grind surfaces after MAF and UAMAF were also analyzed by using SEM images. [ABSTRACT FROM AUTHOR]

Surface integrity of a machining component is crucial in applications like aerospace, automobile and marine industries as it impacts corrosion and fatigue life. In this study, the Ultrasonic Magnetic Abrasion Finishing (UAMAF) setup along with a chemical coating was used to finish the Hastelloy C-276. The responses change in the surface finish (%∆Ra) and material removal (MR) were analyzed using different process variables such as power intensity, voltage, speed, wt.% of abrasives and working gap. Further chemical coating of yttrium acetate and di-ethanolamine was applied to UAMAF specimens using physical vapor deposition. Variables such as weight of etchant, chamber temperature and the number of coatings were considered in the coating process. From the experimental results, it was observed that the surface finish improved with all process parameters except the working gap. The surface finish first increased and then decreased with working gap in the UAMAF process. MR increased with wt.% of abrasives, power intensity, and voltage while it was decreased with working gap and speed. The initial average roughness of the workpiece was Ra = 1.3 µm, and after the MAF process it reduced to Ra = 0.325 µm; further, after UAMAF it reduced to Ra = 0.096 µm, and after chemo based UAMAF, it was reduced to Ra = 0.0224 µm. However, the %∆Ra improved by around 98.3 % before and after processing and the maximum MR observed was 22.19 mg. [ABSTRACT FROM AUTHOR]