Magnetic Abrasive Finishing

Introduction
 Magnetic field–assisted polishing is a nonconventional process in which
the machining forces are controlled by a magnetic field.
 Accordingly, finish polishing is achieved without the need for expensive,
rigid, ultra-precision, vibration- and error-free machine tools by
incorporating the magnetic polishing elements necessary into the existing
machine tools.
 There are two types of magnetic field–assisted polishing:
 Magnetic abrasive finishing (MAF), which uses a brush of magnetic
abrasives for finish machining,
 Magnetic float polishing (magnetic fluid grinding), which uses
magnetic fluid that is a colloidal dispersion of subdomain magnetic
particles in a liquid carrier with abrasives.
 Although MAF originated in the United States during the forties, it was in
the former U.S.S.R.

 and Bulgaria that much of the development took place in the late fifties and
sixties.

 During the eighties the Japanese followed the work and conducted research
for various polishing applications.
The machining system
 A cylindrical workpiece is clamped into the chuck of the spindle that provides
the rotating motion.

 The workpiece can be a magnetic (steel) or a nonmagnetic (ceramic) material;

the magnetic field lines go through the workpiece.

 Axial vibratory motion is introduced in the magnetic field by the oscillating

motion of the magnetic poles relative to the workpiece.
 A mixture of fine abrasives held in a ferromagnetic material (magnetic
abrasive conglomerate, See Fig.) is introduced between the workpiece and the
magnetic heads where the finishing process is exerted by the magnetic field.

 Typically the sizes of the magnetic abrasive conglomerates are 50 to 100

microns and the abrasives are in the 1 to 10 micron range.
 With nonmagnetic work materials, the magnetic abrasives are linked to each
other magnetically between the magnetic N and S poles along the lines of the
magnetic forces, forming flexible magnetic abrasive brushes.
 In order to achieve uniform circulation of the abrasives, the magnetic abrasives
are stirred periodically.
 MAF conditions that caused both surface and edge finishing:
Material removal process
 MAF operates with magneto abrasive brushes where the abrasive grains
arrange themselves with their carrying iron particles to flexibly comply with
the contour of the work surface.
 The abrasive particles are held firmly against the work surface, while short
stroke oscillatory motion is carried out in the axial workpiece direction. MAF
brushes contact and act upon the surface protruding elements that form the
surface irregularities.
 While surface defects such as scratches, hard spots, lay lines, and tool marks
are removed, form errors like taper, looping, and chatter marks can be
corrected with a limited depth of 20 microns.
 The material removal rate and surface finish depend on the workpiece
circumferential speed, magnetic flux density, working clearance, workpiece
material, size of magnetic abrasive conglomerates including the type of
abrasives used, and its grain size and volume fraction in the conglomerate.
 Fox et al. (1994) concluded that the average surface finish Ra of a ground rod
can be finished to about 10 nm.
 Increasing the magnetic flux density raises the rate of finishing.
 High removal rates and the best finish were obtained with an increase in the
axial vibration amplitude and frequency.
 The axial vibration and rotational speed has to be taken into consideration for
obtaining the best cross pattern that would give the best finish and high
removal rate.
 Singh and his team (2004) recommended a high voltage level (11.5 V), low
working gap (1.25 mm), high rotational speed (180 rpm), and large mesh
number for improving the surface quality.
Applications
 Polishing of balls and rollers
 Conventional finishing of ceramic balls, for bearing applications, uses low
polishing speeds and diamond abrasives as a polishing medium.

 The long processing time and the use of expensive diamond abrasives
result in high processing costs.

 Diamond abrasives at high loads can result in deep pits, scratches, and
microcracks.

 Consequently the high processing cost and the lack of the machining
system reliability form possible limitations.

 To minimize the surface damage, gentle polishing conditions are required,

namely, low levels of controlled force and abrasives not much harder than
the work material.
 A recent development in MAF involves the use of a magnetic field to support
abrasive slurries in polishing ceramic balls and bearing rollers (See Fig).

 A magnetic field, containing abrasive grains and extremely fine ferromagnetic

particles in a certain fluid such as water or kerosene, fills the chamber within a
guide ring. The ceramic balls are between a drift shaft and a float.
 The abrasive grains, ceramic balls, and the float (made from nonmagnetic
material) are suspended by the magnetic forces.

 The balls are pre-set against the rotating drive shaft and are polished by the
mechanical abrasion action. Since the forces applied by the abrasive grains are
extremely small and controllable, the polishing action is very fine. The process
is economical, and the surfaces produced have little or no defects.
 Finishing of inner tube surface.
 Clean gas and liquid piping systems need to have highly finished inner
surfaces that prevent contaminant from accumulating.

 When the pipe is slender, it is hard to produce smooth inner surfaces in a

cost-effective way.

 Electrolytic finishing has many problems associated with the high cost of
controlling the process conditions and disposing of electrolyte without
environmental pollution.
 Figure shows the two-dimensional schematic view of the internal
finishing of a non-ferromagnetic tube using MAF.
 The magnetic abrasives, inside the tubes, are converged toward the
finishing zone by the magnetic field, generating the magnetic force
needed for finishing.
 By rotating the tube at a higher speed, the magnetic abrasives make the
inner surface smoother.
Other MAF applications.

 The process can be applied in many other fields, as described by Khayry

(2000), Umehara et al. (1997), and Hitomi and Shinmura (1995):

1. Polishing of fine components such as printed circuit boards

2. The removal of oxide layers and protective coatings
3. Chamfering and deburring of gears and cams
4. Automatic polishing of complicated shapes
5. Polishing of flat surfaces
Reference
H. Ag. El-Hofy, “Advance Machining Processes”, Mcgraw-hill publication
(Mechanical Engineering series).

Kalpakjian. S, (1997) “Manufacturing Process for Engineering Materials”,

Reading; MA: Addison-Wesley. (khai.itl.net.ua/eng/ttc/204)

Metals Handbook, (1989), Vol. 16, “Machining” Materials Park; OH: ASM
International.
Thank You