Experimental study and empirical modelling of magnetic abrasive finishing on ferromagnetic and non-ferromagnetic materials

Magnetic abrasive finishing is one of the advanced finishing processes where in the iron (Fe) particles form a flexible matrix in which the abrasives are trapped when magnetic field is applied. In the present paper, the magnetic flux densities (MFD) are measured at various distances from the outer surface to centre on ferromagnetic and non–ferromagnetic materials with approximately same hardness. MFD is about three times higher on ferromagnetic compared to non–ferromagnetic workpiece. Complete experimental study is carried out and empirically modelled. Best final Ra value about 20 nm and 60 nm is achieved on ferromagnetic and non–ferromagnetic stainless steel, respectively. With increase in abrasive mesh size and decrease in working gap, percentage change in Ra (%ΔRa) increases. Online measurement of forces is done using indigenously developed ring type dynamometer. Normal magnetic force is much higher in case of ferromagnetic than non–ferromagnetic workpiece material but no significant change is found in tangential cutting force.