Abstract
Finishing of cylindrical workpieces of SUS304 steel has been done using loosely bonded diamond based magnetic abrasives prepared by homogeneous mixing of magnetic powder (Fe powder of 300 mesh size (51.4μm)), abrasive powder (Diamond particles of 200 mesh size (41μm)), and lubricant. A central composite design involving four variables has been employed using RSM techniques to establish a mathematical model between parameters and response (percent improvement in surface finish), a series of experiments have been conducted using in-house fabricated setup. It has been found that magnetic flux density, quantity of magnetic abrasives, rotational speed of workpiece and percentage of abrasives in magnetic abrasives has significant effect on PISF. The maximum percentage improvement in surface finish was found to be 81% (0.04 μm Ra) at 1.0 Tesla of magnetic flux density, 40 mg of magnetic abrasives, 800 rpm as rotational speed of workpiece and 40% of abrasive. Scanning Electron Microscope (SEM) photographs shows that the surface generated by turning on lathe consists of deep scratches. The peaks have been sheared off to much smaller heights by MAF resulting in improved surface finish, but fine scratching marks produced by MAF appear on the surface.
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