Experimental comparison of unbonded, agglutinated and sintered SiC-based magnetic abrasive particles in magnetic abrasive finishing process

Abstract

Aluminum grabs a spot in the top ten light metals and henceforth finds a wide range of applications in the aerospace industry and other concerned/allied industries. A high surface finish is obligatory in a few components. The objective of this research is to compare and analyze the internal surface finish obtained by unbonded, agglutinated, and sintered silicon carbide (SiC) based magnetic abrasives in aluminum pipes using magnetic abrasive finishing process. Scanning electron microscopy and atomic force microscopy (AFM) have aided in a close inspection of the topography of the surfaces. AFM topographic images indicate that sintered magnetic abrasive particles yielded a surface roughness value (Ra = 17.7 nm) followed by agglutinated (Ra = 34.98 nm) and unbonded magnetic abrasive particles (Ra = 99.3 nm). Maximum percentage improvement in surface finish (PISF) of 87 % in terms of Ra has been obtained at rotational speed of workpiece (1000 rpm), magnetic flux density (0.85 Tesla), quantity of abrasive particles (15 gm), size of abrasives (80 μm) and machining time (30 mins.).