Abstract
Cylindrical electro-chemical magnetic abrasive machining (C-EMAM) is an advanced abrasion-based hybrid machining process used for efficient finishing of cylindrical surfaces made of difficult-to-machine electrically conducting materials. In this work, experiments were performed on self-developed C-EMAM process setup to investigate the effects of electrolytic current, current to electromagnet, workpiece rotational speed and frequency of vibration on performance of the process during machining of magnetic stainless steel (AISI-420) using unbonded magnetic abrasives. The performance of the process is evaluated in terms of material removal and surface roughness. It is observed that for magnetic steel, magnetic abrasion has significant contribution in material removal, whereas electro-chemical dissolution helps rapid reduction in surface roughness due to abrasion passivation-synergism at peaks of surface profile. Workpiece speed and current to electromagnet have greater effect on synergy of material removal.
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