Abstract
As the precision of the manufacturing process and the quality of ferromagnetic parts are further enhanced, surface topography is playing a significant role in guaranteeing the service performance and lifetime of mechanical parts. Thus, a novel magnetic focusing method (MFM) that is not susceptible to a hostile environment in a sophisticated and online manufacturing process is proposed, which is demonstrated to be an effective and feasible technique with higher detection resolution and a higher signal-to-noise ratio (SNR). By a theoretical introduction of the magnetic focusing mechanism and finite element simulations and calculations for six main MFM sensor structural parameters, the MFM sensor characterizations and optimal structural parameters are presented. Furthermore, the feasibility and validity of the proposed novel method and sensor in surface topography inspection for ferromagnetic materials were verified in the experiments. Finally, the advantages and disadvantages of the common surface topography testing methods were compared. These results demonstrate the great promise in the application of MFM and the corresponding sensor in practical engineering.
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