Abstract
In magnetorheological (MR) fluid polishing, high magnet speed releases abrasive particles from the finishing region, reducing their grip on the ferromagnetic chain structure and triggering the process to stall. Enhancing polishing efficiency necessitates developing a new composite magnetic abrasive (EIP-Al2O3) through microwave sintering. EIP-Al2O3 has favourable soft magnetic effects when it comes to its structure, phase composition, magnetic, and rheological properties. Chemo-mechanical magneto-rheological finishing (CMMRF), a developed hybrid-finishing method, aims to thoroughly evaluate CMA's performance. CMA attains a defect-free Al-6061 surface with Ra ∼79 nm and MRR ∼0.379 mg/min. CMAs outperforms simply mixed abrasives (SMA) by a significant 25 % increase in Ra and a remarkable 60 % increase in MRR. CMAs emerges as an effective solution for combating tool aging effects at high rotational speeds.
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