Magnetic abrasive finishing: Innovations and possibilities

Magnetic abrasive finishing (MAF) has emerged as a leading nano-finishing technology, offering precision and versatility across diverse materials. This review comprehensively examines MAF principles, classification, modeling-simulations, optimization techniques, and hybrid processes. Extensive experimental studies on surface finishing across varied materials and geometries are analyzed, highlighting influential process parameters and the role of magnetic abrasives. Various types and preparation methods of magnetic abrasives are discussed, along with the significance of magnetic tool geometry and sources. Modeling simulations addressing material removal, surface roughness, and temperature prediction are explored. The review concludes with discussions on applications, challenges, and future research avenues, emphasizing MAF's value in addressing complex parts and geometries. Recommendations include integrating standardization, automation, and innovative strategies to amplify MAF's relevance in mass production scenarios. Key findings reveal MAF's precision and versatility in achieving nano-level surface finishes, with recommendations for optimized magnetic abrasive utilization. Challenges in high-accuracy component mass production are identified, along with strategies to enhance efficiency and effectiveness in MAF applications. Overall, this review provides valuable insights for researchers, practitioners, and academicians seeking comprehensive knowledge of MAF.