Magnetic Abrasive Finishing Process Research Articles

Study on temperature and hardness behaviors of Al-6060 alloy during magnetic abrasive finishing process using artificial neural networks

Magnetic Abrasive Finishing (MAF) revolutionizes surface finishing by utilizing magnetic fields to apply pressure, ensuring exceptionally high-quality surfaces. Its potential for ultra-precise finishing with fine magnetic abrasives is particularly noteworthy. This study analyzes subsurface temperature dynamics during the MAF process on Al-6060, recognizing temperature's pivotal role in shaping surface texture and mechanical-chemical properties. Unbonded magnetic abrasives containing SiC were used without lubrication or coolants in experimentation. Experimental parameters, including machining gap, abrasive weight, voltage, and rotational speed, were systematically varied using a Box-Behnken Design of Experiments. An artificial neural network facilitated comprehensive data modeling, enabling a detailed parametric study. Post-processing surface characterization provided crucial insights into the impact of surface temperature rise on surface finish and hardness. This holistic approach enhances understanding of temperature's influence on MAF efficacy and its outcomes on Al-6060 surfaces. Experimental findings demonstrate MAF's effectiveness in achieving low-temperature finishing of Al-6060, with a maximum surface temperature of 36ºC. ANOVA analysis quantitatively determined that voltage has greatest influence (55.56%), followed by abrasive weight (20.00%) and machining gap (13.89%), with rotational speed having the least impact (2.22%). Qualitatively, the developed ANN model accurately predicted changes in surface roughness (ΔRa), temperature (ΔT), and hardness (ΔH), with maximum errors of 4.107%, 5.588%, and 6.680%, respectively. XRD analysis provided quantitative evidence of SiC diffusion into the surface, resulting in a hardness increase from 2.7 HV to 5.6 HV. Additionally, chemical substrates deposition, such as silicon carbide, kaolinite, iron silicide, and cristobalite, elucidated chemical-mechanical interactions during the process at such low temperatures.

Fuzzy Logic Based Model to Predict Surface Roughness of Si(100) Wafer Using Preliminary Experimental Data Obtained From Single Pole Magnetic Abrasive Finishing Process

Fuzzy Logic Based Model to Predict Surface Roughness of Si(100) Wafer Using Preliminary Experimental Data Obtained From Single Pole Magnetic Abrasive Finishing Process

Optimizing the five magnetic abrasive finishing factors on surface quality using Taguchi-based grey relational analysis

The effectiveness of the magnetic abrasive finishing (MAF) process relies on several factors, including the brush’s flexibility that varies across tools. This study aimed to optimize the results of five key parameters (voltage, finishing time, gap distance, rotating speed, and particle size) on surface roughness (SR) and microhardness (HV) using the grey relational analysis (GRA) method. Experimental work employed the Taguchi design with L27 trials in Minitab 17, involving five variables with three levels for each. The impact of these parameters on microhardness and surface roughness for stainless steel SUS420 bubble cups was assessed using Taguchi and regression analyses. The best roughness improvement and the most substantial enhancement in microhardness were individually obtained with the GRA method. This method assigned the best results for both surface roughness and microhardness. According to Taguchi analysis, the voltage parameter has the main or maximum parameter effect on grade, followed by gap distance, time, spindle speed, and particle size. It was found that the optimal parameters were the same as the input parameters.

Surface Polishing of an Inconel 625 Bar by a Super-Fast MAF Process for a Solenoid Valve Stem Used in a Hydrogen Tank

This study explores a super-fast magnetic abrasive finishing (MAF) process for polishing the surface of an Inconel 625 bar workpiece for a hydrogen solenoid valve stem. The Inconel 625 bar was chosen to replace the existing STS 316 bar material, previously used for a hydrogen solenoid valve stem. The cylindrical surface of Inconel 625 bars was polished by a super-fast MAF process with high rotational speeds of 1000, 5000, 15,000, and 25,000 RPM and a super-strong magnetic field of 550 mT. The polishing characteristics of this process were evaluated according to the type of abrasives, rotational speeds of the workpiece and processing time. As a result, a super-smooth Inconel 625 bar was successfully achieved, with a surface roughness (Ra) reduced from 0.31 μm to 0.02 μm under the optimal conditions (15,000 RPM, CNT particles (0.04 μm), PCD diamond abrasive (1 μm), Fe (#200), 0.5 g of light oil, and 16 min of processing time). Also, the Ansys analysis results showed suitable strain, equivalent stress, and safety factor of the Inconel 625 bar. This confirmed that, after a super-fast MAF process, an Inconel 625 bar is feasible for application in Hydrogen (H2) tanks instead of a conventional STS 316 bar.

Measurement from the residual stresses on magnetic abrasive finishing process by utilizing steel sheet 201

Measurement from the residual stresses on magnetic abrasive finishing process by utilizing steel sheet 201

The Impact of Magnetic Abrasive Finishing (MAF) Process Parameters on the Microhardness of Stainless Steel SUS420 Bubble Cups

The Impact of Magnetic Abrasive Finishing (MAF) Process Parameters on the Microhardness of Stainless Steel SUS420 Bubble Cups

Development and experimentation of free-form magnetic abrasive finishing process for the application of bearing surfaces

Development and experimentation of free-form magnetic abrasive finishing process for the application of bearing surfaces

Development and experimentation of Free-form Magnetic abrasive finishing process for the application of bearing surfaces

Development and experimentation of Free-form Magnetic abrasive finishing process for the application of bearing surfaces

Development and experimental investigation of magnetic abrasive finishing of 17-4PH steel

Magnetic abrasive finishing (MAF) is a promising process for achieving better surface finish, not only on softer materials, but also on harder materials. In several industries, 17-4PH steel has predominantly being used due to its exceptional properties of better corrosion resistance, high strength-to-weight ratio, and ease of weldability. In this article, the details of a developed MAF attachment for a CNC vertical milling machine are presented. The developed attachment was used to finish the surface of 17-4PH steel and is suitable for plane workpiece surface. Effect of various MAF process parameters such as rotational speed of electromagnet, supply voltage/current, abrasive mesh number, and working gap were studied on 17-4PH steel for material removal rate (MRR) and percentage change in surface roughness (PCSR) using one-factor) using one-factor-at-a-time approach (OFAT). Based on experimental results, on increasing voltage/current, increase in MRR and PCSR was observed; however, decrease in PCSR and MRR was noticed with increase in the working gap. PCSR was increased up to 600 rpm of electromagnet and 600 mesh number. However, on further increase in speed and mesh number, resulted in decrease in PCSR. Supply voltage/current was the most significant input process parameter on PCSR for the constant values of others parameters. Maximum PCSR of 90.37% was observed at 1.5 mm working gap, 600 rpm rotational speed, 600 mesh number and 24 V/0.9A voltage/current. The results reported in the article are useful in identifying the relative significance of parameters for the selected workpiece material.

INVESTIGATION OF SURFACE ROUGHNESS IN MODERN FINISHING PROCESS USING PERMANENT MAGNET

This work introduces an investigation of the surface roughness (Ra) during flat plate machining utilizing magnetic abrasive finishing process (MAF). In this study three parameters (Machining time, Mesh size, and Gap) were studied. The MAF tool is made from permanent magnet and the abrasive powder is consisting of 40% of SiC and 60% Fe powder with three Mesh size (100, 250, and 400 µm). The Taguchi L9 array was used in designing the experiments. The results show that the increasing machining time caused a decrease in Ra. The increase in mesh size and the gap will increase the surface roughness. The dominant factor that affect the surface roughness was the machining time due to enough time to machine the target surface.

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

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.).

A Study on Using Magnetic Abrasive Finishing with a 6-Axis Robot to Polish the Internal Surface Finishing of Curved Tubes

This study proposed a new magnetic abrasive finishing (MAF) method, in which a 6-axis robot with a magnetic machining tool was used to polish the inner surfaces of curved tubes. We have also developed a magnetic machining tool jig, which can be fixed at the front of the 6-axis robot, rotating freely and suitable for polishing the inner surfaces of curved tubes. In this study, we focused on investigating the machining parameters in the initial machining stage and precision finishing stage. Based on the characteristics of machining parameters, a multi-stage MAF process was conducted to obtain an inner surface with high quality and high efficiency. The experimental results showed that both the roughness Ra and Rz of inner surface in the initial machining stage significantly decreased with the increase in the mixed magnetic abrasives, to as low as less than 20 nm Ra in the precision finishing stage when the machining parameters were appropriately adjusted. In addition, the roughness Ra of inner surface could be further reduced to less than 10 nm Ra in the multi-stage MAF process. Finally, the magnetic flux density cloud map and the magnetic field line distribution map were analyzed in Ansys Maxwell.

A novel auto-gaping magnetic pole system for inner surface finishing of non-circular pipes using magnetic abrasive finishing process

This study explored the design of a novel auto-gaping magnetic pole system for finishing the inner surface of non-circular pipes using a magnetic abrasive finishing (MAF) process. Non-circular pipes are widely used for the transportation of ultra-high purity substances, including gases and fluids in many industries for semiconductor, medical, and aerospace applications. MAF process typically utilizes non-movable magnetic poles. However, due to the noncircular cross-section of the pipe, the magnetic flux density, produced by non-movable magnetic poles, across the polishing surface will exhibit huge variations, resulting in uneven and poor finish at some areas. The proposed auto-gaping magnetic pole system allows the magnetic poles to move so that they can track the workpiece surface to keep the gap between the magnetic pole and workpiece’s external surface constant. As a result, the magnetic densities can be maintained at desired values to achieve even and effective finishing by MAF process. Elliptical pipes were used as the non-circular pipes for experimental validation under different MAF process parameters. The results showed that this novel technique for inner surface finishing of a non-circular pipe is capable of improving the surface roughness, reducing the Ra values from over 0.20 μm to 0.05 μm or lower, across the entire inner surface of the elliptical pipe. In addition, superior material removal efficiency was achieved. The results demonstrate that the MAF process combined with a novel auto-gaping magnetic pole system is feasible to produce the ultra-smooth inner surface of non-circular pipe.

Nanoscale Polishing Technique of Biomedical Grade NiTi Wire by Advanced MAF Process: Relationship between Surface Roughness and Bacterial Adhesion.

Nitinol (NiTi), an alloy of nickel and titanium, wires are an important biomedical material that has been used in catheter tubes, guidewires, stents, and other surgical instruments. As such wires are temporarily or permanently inserted inside the human body, their surfaces need to be smoothed and cleaned in order to prevent wear, friction, and adhesion of bacteria. In this study, NiTi wire samples of micro-scale diameters (i.e., Ø 200 μm and Ø 400 μm) were polished by an advanced magnetic abrasive finishing (MAF) process using a nanoscale polishing method. Furthermore, bacterial adhesion (i.e., Escherichia coli (E. coli), and Staphylococcus aureus (S. aureus)) to the initial and final surfaces of NiTi wires were investigated and compared in order to assess the impact of surface roughness on bacterial adhesion to the surfaces of NiTi wires. The finding revealed that the surfaces of NiTi wires were clean and smooth with a lack of particle impurities and toxic components on the final surface polished using the advanced MAF process. The surface roughness Ra values of the Ø 200 μm and Ø 400 μm NiTi wires were smoothly enhanced to 20 nm and 30 nm from the 140 nm and 280 nm initial surface roughness values. Importantly, polishing the surfaces of a biomedical material such as NiTi wire to nano-level roughness can significantly reduce bacterial adhesion on the surface by more than 83.48% in the case of S. aureus, while in the case of E. coli was more than 70.67%.

Ultrasonic assisted magnetic abrasive finishing of DIN 1.2738 tool steel using vitrified bonded magnetic abrasive particles

Ultrasonic-assisted magnetic abrasive finishing (UAMAF) process has been developed to reduce the finishing time of hard materials. In this process, in addition to the rotation of the magnetic tool, ultrasonic vibrations are also applied to the workpiece simultaneously in the longitudinal direction. In the present work, the effects of UAMAF process parameters, including ultrasonic power, the rotational speed of the magnetic tool, working gap, and weight of magnetic abrasive particles (MAPs) on the percentage change in surface roughness (%ΔRa) of 1.2738 tool steel are discussed with an experimental approach. In this regard, besides the development of the UAMAF process, the sintering of MAPs with glass powder is proposed. The experiments are designed according to the Taguchi method. Then, the input parameters of the UAMAF process are modeled and optimized using the signal-to-noise (S/N) ratio analysis to achieve the maximum %ΔRa. Statistical analysis of experimental data shows that the most significant contribution in improving %ΔRa is attributed to the weight of MAPs. Furthermore, according to the comparative study, %ΔRa in the UAMAF process for finishing the DIN 1.2738 tool steel is improved by 86.62% under optimized conditions. In comparison, this value in the MAF process is equal to 48.62% under the same conditions. The results of the surface morphology also underline that abrasive particles in the UAMAF process hit the peaks of the surface roughness due to vibration applied to the workpiece, which leads to a high-quality finished surface.

Electrolytic magnetic abrasive finishing process – A review

Electrolytic magnetic abrasive finishing process – A review

Experimental investigation of aluminium 2024 alloy using cylindrical magnetic abrasive finishing process

In super finishing operations, the magnetic abrasive finishing (MAF) method is being researched as the Predominant finishing method. A cylindrical MAF (CMAF) method that was developed internally has undergone experimental investigation to improve the surface qualities of the aluminium 2024 alloy (Al 2024). For the machining process, a mixed abrasive of Al2O3 and SiC was utilized. Variable process factors for the experimental investigation include voltage, speed, and the percentage of abrasives. Based on results, the surface finish of the workpiece had improved to 94.12 % from its initial surface finish with a maximum of 11.5 mg of metal removed from the surface. Nevertheless, throughout the experimentation, the temperature that develops on the work surface as a result of the abrasives' shearing action is less than 57 °C.

Study on Elucidation of the Roundness Improvement Mechanism of the Internal Magnetic Abrasive Finishing Process Using a Magnetic Machining Tool

The magnetic abrasive finishing process using the magnetic machining tool was proposed to finish the internal surface of the thick tube (the thickness of the tube is 5~30 mm). It has been proved that this process can improve the roundness while improving the roughness. In this paper, we mainly study the machining mechanism of roundness improvement. Firstly, the influence of finishing characteristics on the roundness improvement was discussed, including the rotational speed of the magnetic machining tool and the rotational speed of the tube. It was concluded that the roundness improvement increases with the increase in the rotational speed through the analysis of finishing force and finishing times. Furthermore, the influence on roundness improvement of different distributions of magnetic particles were experimentally compared. After finishing, due to the magnetic force generated by the magnetic machining tool and the magnetic pole unit exerting pressure on the magnetic particles, a fixed magnetic brush is formed. The experimental results show that the circumferential length of the fixed magnetic brush is different due to the different distribution areas of magnetic particles. It was concluded that the roundness improvement increases with the circumferential length of the fixed magnetic brush increases by discussing the relationship between the circumferential length of the fixed magnetic brush and the wavelength of the roundness curve. When the circumferential length of the fixed magnetic brush is 76 mm, the roundness was improved from 379 μm to 236 μm after 60 min of finishing.

A novel methodology of MAF process via a multi-axis/multi-faceted polishing technique for enhancing surface quality of artificial hip joint component

This paper explores a novel methodology of magnetic abrasive finishing (MAF) process via a multi-axis/multi-faceted polishing technique to achieve a high surface accuracy of artificial hip joint component such as femoral head used in the field of biomedical engineering. In this process, movement actions are adapted to multiple axes on X, Y, Z, and A directions in the MAF process. Movement of eco-friendly polishing media was driven by magnetic poles on X and Y directions. These eco-friendly polishing media strongly acted against the rotational/vibrational surface of femoral head, creating a multi-faceted polishing of femoral head. Results showed that a novel methodology based on the multi-axis/multi-faceted polishing technique could achieve an ultra-fine and smooth surface polishing of femoral head within a short polishing time of 12 min without causing defects on the surface of a femoral head sample. An average surface roughness value (Sa) of femoral head was successfully improved from 0.301 μm to 0.044 μm. The average improvement in percentage change in Sa of femoral head as 85.38 % was achieved, resulting in the ultra-smooth surface polish on the femoral head surface. Results of this study validated the capability of a novel methodology of MAF process as an efficient and effective technique to achieve an ultra-smooth surface polish for medical components with advantages for biomaterials and biomedical engineering industry.

Modelling of finishing forces on Hastelloy C-276 using ultrasonic assisted magnetic abrasive finishing process

Modelling of finishing forces on Hastelloy C-276 using ultrasonic assisted magnetic abrasive finishing process