On the temperature analysis of magnetic abrasive finishing of aluminum 6060 using finite element method

Abstract

Magnetic abrasive finishing (MAF) process is the superfinishing process used to enhance the surface quality of metallic and nonmetallic materials such as alloys, composites and ceramics etc. This process erodes material from a workpiece surface in the form of micro-chips with the help of flexible magnetic abrasive brush (FMAB) in working gap with the presence of a magnetic field. This process generates heat due to rubbing action that produced by FMAB between the interface surface of FMAB-workpiece. Thermal stability of the finishing surface of workpiece is vital during finishing of MAF process because it affects the surface texture and surface integrity. Measuring surface temperature at the interface of FMAB-workpiece during finishing is very tough in MAF process. In the present study, finite element analysis (FEA) is used for simulation of magnetic flux distribution and surface temperature distribution of interface surface of aluminum 6060 workpiece-FMAB of MAF process. FEA predicts the magnetic flux density in between 0.429 T and 1.263 T for current between 3.0 A and 6.0 A) and surface temperature distribution in the range of 27.33 ºC–34.92 ºC for different processing conditions of process parameters. FEA simulated results are validated by comparing with experimental finding and estimated error between simulated and experimental results are in the range of 4.94%–10.26%. Finally, the present developed FEA is employed on the mild steel workpiece to cross-examine the simulated behavior of magnetic flux density and surface temperature at the finished interface surface of mild steel.