Analysis of magnetic abrasive finishing with slotted magnetic pole.

Magnetic Abrasive Finishing (MAF) is relatively a new finishing process among the advanced finishing processes in which the workpiece is kept in the magnetic field created by two poles of an electromagnet. The working gap between the workpiece and the magnet is filled with magnetic abrasive particles. A flexible magnetic abrasive brush is formed, acting as a multipoint cutting tool, due to the effect of magnetic field in the working gap. This process is capable of producing the surface finish of nanometer range. Most of the researchers have been using the electromagnet having a slot in it to improve the performance of the process but hardly any information is available about its effect on the process performance. This paper deals with the effect of a slot made in the electromagnet on the forces and surface quality during MAF. An experimental set-up is designed and fabricated for the measurement of the magnetic field distribution in the working gap. The magnetic field is simulated using a finite element model of the process. The magnetic field is also measured experimentally to validate the theoretical results. It indicates a good agreement between the experimental results and simulated values. The finite element method is further used for the evaluation of the magnetic force and surface quality during MAF. To our surprise it is found that the force under the slot is negative, even then process performance is improved. MAF process removes a very small amount of material by indentation and rotation of the magnetic abrasive particles in the circular tracks. Due to rotation of the magnetic abrasive flexible brush, grooves are formed on the workpiece surface which decides the surface profile after MAF. Surface quality is determined on the basis of the surface profile achieved by equating the volume of groove produced. These results show an improvement in finishing rate while using a slotted pole surface. © 2004 American Institute of Physics [ABSTRACT FROM AUTHOR]