Magnetic flux leakage (MFL) characterization of hard magnetic material (HMM) plays a significant role in the service performance and structural health monitoring of magnetic and mechanical parts. Quantitative simulation study and theoretical analysis in HMM surface topography inspection were conducted for the first time. Starting with the background introduction of electromagnetic theories in HMM surface topography inspection, four typical surface models and function relations were built and confirmed quantificationally. By large numbers of quantitative simulations and analysis of different HMM surface topographies, it can be found that both magnetic enhancement region and cavity exist. Furthermore, the self-magnetization effect forms the magnetic enhancement region, and magnetic cavity is mainly caused by the magnetic compression effect. Finally, the fitted function relationships applied to reconstruct the surface parameters with small estimated errors laid a solid theoretical foundation to the quantitative surface topography measurement in practical applications. Thus, an overall measurement theory for ferromagnetic material was built through the supplement of HMM surface topography characterization.
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