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Abstract
The attempts of researchers to obtain accurate and high-quality surfaces have led to the invention of new methods of finishing. Magnetic abrasive finishing (MAF) is a relatively new type in which magnetic field is used to control the abrasive tools. Surfaces of moulds, for instance, are among those which require very high-surface smoothness. Usually, this type of part has freeform surfaces. In this study, the effect of magnetic abrasive process parameters on finishing freeform surfaces of aluminium parts has been examined. This method was achieved through a combination of the magnetic abrasive process and computer numerical control. The use of a simple hemisphere to be joined on the flat area of the magnet as well as spark machining for forming a sphere at the end of a magnet were performed during experimentation. Gap, rotational speed of the machining head, amount of abrasive powder and feed rate were among the parameters that were tested in experiments. The design of experiments is based on the response surface methodology. Significant parameters and the regression equations governing the process were also determined. The impact of intensity of the magnetic field was obtained using MAXWELL finite element software. In the MAF process, magnetic abrasives play the role of cutting tools. However, the magnetic abrasives are not easily available as these are produced by special techniques such as sintering method, adhesive based, plasma based or gel based. This study presents the basic polishing characteristics of the magnetic abrasives produced by the mechanical alloying process. After the mechanical alloying process fine magnetic abrasives are obtained, in which the abrasive particles adhere to the base metal matrix without any bonding material. In this study, investigation was performed only on the convex area of workpiece. Optimum parameters are gap size of 0.5 mm, feed rate of 10 mm min−1 rotational speed of 2100 rev min−1 and powder amount of 1.75 g. To help understand the effectiveness of the MAF process, scanning electron microscopy and atomic force microscopy of the machined surfaces have been carried out.