Ultra-Precision Finishing by Magnetic Abrasive Finishing Process

Present study aims to achieve nano-finish on non-ferrous metal by magnetic abrasive finishing (MAF) method. Extensive work is carried out to design and develop a suitable magnetic tool to achieve high surface finish of a component in a very short time. To retain magnetic abrasives at the center of the tool and to maximize process efficiency, a four pole arrangement magnetic tool has been designed and in addition an Nd-FeB magnet is configured below workpiece. From magneto-static simulations, magnetic flux density was observed to be 1.8 times higher when Nd-FeB magnet was configured below the workpiece than workpiece configured without a magnet Experiment was carried out using un-bonded magnetic abrasive media with diamond abrasives and diesel as a bonding media. Effect of critical process parameters such as circumferential speed, feed and working gap of process on surface finish improvement were studied and optimized. By performing experiments with optimized process parameters i.e. speed 600RPM, feed 75mmimin and gap of 1mm. surface roughness improvement from 0.3um to 22nm was achieved with NNNN-S tool arrangement in 24 passes for 100mm length SS304 workpiece. Characterization of finished surface was performed using surface profilometer and atomic force microscope to understand the tool interaction on work component in MAF process. (C) 2017 Elsevier Ltd. All rights reserved.