Enhancing Surface Integrity: A Review of Magnetic Abrasive Finishing in Crack Fatigue Layer Removal

Magnetic abrasive finishing (MAF) is an advanced surface finishing technology that utilizes magnetic fields to control abrasive particles, enabling precise material removal and superior surface integrity. This review paper comprehensively analyzes MAF research from 2015 to 2024, focusing on key developments, process optimizations, and industrial applications. The study looks at how MAF affects different materials like titanium alloys, stainless steels, and 3D-printed parts, showing how it improves surface smoothness, leftover stress, and resistance to wear and tear. This review paper expands on the experimental investigation of MAF’s efficacy in removing crack fatigue layers for a high-cost product to give it a high performance and longer life, a critical aspect in enhancing the functional performance of components. It is synthesizing various studies that explore the principles of MAF, the preparation of magnetic abrasives, tool design, and the process’s modeling and simulation. It also examines the force measurement and material removal mechanisms, providing a comprehensive understanding of the process parameters and their optimization. It is highlighting the challenges faced ‎in the field and suggests future directions for research, aiming to contribute to the development of more efficient and precise finishing techniques in manufacturing industries. The findings of this study are expected to benefit researchers and practitioners in MAF-related fields, paving the way for innovations in surface finishing technologies.