Abstract
Soft magnetic powder cores are materials manufactured by pressing pure iron powder covered with insulating film into shape. These are widely known soft magnetic materials which are used as essential electromagnetic conversion parts in automobiles and household appliances. In recent years, demand for higher magnetic properties and dimensional precision has been growing with respect to soft magnetic powder cores. It has therefore become necessary to develop a high-efficiency, high-precision finishing method. The issues to be addressed with regard to this kind of method are: (1) the pure iron used in these materials displays ductility resulting in burring and cohesion to machining tools, (2) these materials are green compacts with low binding forces between powder particles and high tendencies towards cracking and gouging, and (3) these materials possess residual pores at levels of several percent thus resulting in microscopically intermittent processing which causes heavy machining tool wear. We have solved these issues through the development of a super-smooth finishing method designed for soft magnetic powder cores.
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