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ABSTRACT
This paper covers the development of a multilayer icebonded abrasive polishing (IBAP) tool for multistage polishing of Ti-6Al-4V alloy specimens based on a systematic study that determined the number of layers, thickness of each layer, and the type, size and concentration of abrasives in each layer. Based on this study, a three-layered IBAP tool with the bottom layer consisting of soft aluminum oxide abrasives of 3 µm size with 5% concentration, the middle layer with moderately hard silicon carbide abrasives of 8 µm size with 10% concentration and the top layer with hard boron carbide abrasives of 15 µm size with 30% concentration was formulated for ultrafine finishing of Ti-6Al-4V alloy specimen in a single setup. The performance of the three-layered IBAP tool assessed in terms of finish and morphology over the work surface showed 81% improvement in surface finish, showing its effectiveness over a single-layered IBAP tool. Polishing studies have clearly demonstrated the generation of ultrafine surfaces, yielding a finish of 37 nm while the morphological studies on the polished surface have shown a nearly scratch-free surface on the Ti-6Al-4V alloy.