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Materials Today: Proceedings 5 (2018) 20455–20463 www.materialstoday.com/proceedings

ICMPC_2018

Advances in Magnetic Abrasive Finishing for Futuristic

Requirements - A Review

Rajneesh Kumar Singha*, D.K. Singhb and Swati Gangwarc

a
Department of Mechanical engineering, Madan Mohan Malaviya University of Technology, Gorakhpur 273010, India
b
Director, Rajkiya Engineering College, Azamgarh, 276201, India
c
Assistant Professor, Department of Mechanical engineering, Madan Mohan Malaviya University of Technology, Gorakhpur 273010, India

Abstract

Magnetic abrasive finishing (MAF) process is an advance machining process that produces high quality surface by removing material from the
work piece surfaces. The magnetic abrasive finishing process have been classified according to finishing profile of surface i.e. cylindrical surface
finishing, inner surface finishing and plane surface finishing. This paper summarized better understanding about the experimental work that had
been performed on process and response parameters. The surface roughness and material removal highly depend on machining gap and magnetic
flux density. The importance of mathematical modelling and simulation, finite element method for modelling and simulating of magnetic forces,
Surface roughness and surface temperature to improve the performance of the magnetic abrasive finishing process has bee also described in this
paper. Super-alloy, composites and advanced ceramics can be effortlessly finished by using different type of MAF process. Different monitoring
and control system also have been studied by many researchers for superior regulatory of process performance parameters of magnetic abrasive.
At last this paper reveal the influence of alternating parameters of different field in MAF process and it have excellent scattering effect.

© 2018 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of Materials Processing and characterization.

Keywords: Magnetic Abrasive Finishing; Magnetic Abrasive Particles; Surface quality enhancement.

1. Introduction

Magnetic abrasive finishing process (MAF) was invented in the United States in 1940’s for achieving super-
finishing of advanced material such as super-alloys, composites and ceramics. MAF had ability to remove material
in microns and enhanced surface texture greatly. Later in mid decades, Boron and his colleagues in the Soviet Union
were pioneer to develop this process. They implemented this process to finish high value critical components that
were cutting tools, turbine blades, air foils etc. It was Japanese who completely evolved this process and Shinmura
and his colleagues did bulk of work in this field in 1990’s. finally, this had become versatile enough to finish
surgical tools, artificial metallic body parts, space application, too [4].
* Corresponding author.
E-mail address: rajneeshsingh_rsme@mmmut.ac.in

2214-7853 © 2018 Elsevier Ltd. All rights reserved.

Selection and/or Peer-review under responsibility of Materials Processing and characterization.
20456 Rajneesh Kumar Singh et al./ Materials Today: Proceedings 5 (2018) 20455–20463

Magnetic abrasive finishing was done by placing the magnetic abrasive particles (MAP) in working gap that lied
between the work piece and poles.

of a magnet. Magnetic abrasive particles formed by homogenous mixture of magnetic particle (ferrous particles)
and abrasive particles (Al2O3, Diamond or SiC). Further MAP can be characterized into three types- unbounded,
semi-bounded and bounded [3]. A magnetic field was produced between the poles of magnet which helped in
generation of flexible magnetic abrasive brush (FMAB), when magnetic abrasive particles were placed in it. FMAB
acted as multipoint cutting head to remove material from surface of work piece. Finishing on surface of work piece
was done by two mechanisms - indentation and micro chipping. Indentation was done by normal magnetic force
which produced by pushing magnetic abrasive brush into work piece and the micro chipping was done by tangential
cutting force which was produced by rotation of the magnetic brush. Higher the forces, higher would be material
removal from the surface of work piece. [12]
Classification and effect of process parameters on magnetic abrasive finishing had been reported in this paper.
The classification had been done according to the finishing profile of the surface of work piece. Basically, it had
been classified into cylindrical surface finishing, inner surface finishing and plane surface finishing. This paper
particularizes the experimental findings that were contributed by other researches. The major areas of experimental
research are process parameters and their effect on response parameters. The significant process parameters that
affect performance of the MAF are Magnetic Flux density, machining gap, composition, Rotation Speed of the tool
and axial vibration of work piece. The major prominence had been given on Modelling, simulation, process
monitoring & control and importance of alternating field MAF had been discussed.

2. Classification of Magnetic Abrasive Finishing on Basis of Finishing Surface

2.1 Cylindrical surface finishing by using MAF process

Shinmura.T [25] et al. constructed cylindrical MAF process to finish outer surface of cylindrical work piece.
The set-up was constructed by mounting magnet on lathe machine having north and south poles. Magnetic field was
generated from north pole and flowed toward south pole. In this process magnetic abrasive particles were made of
diamond coated magnetic abrasives. Flexible magnetic abrasive brush was formed, when magnetic abrasive particle
aligned magnetically with magnetic forces while they were placed between poles and surface of cylindrical
workpiece under influence of magnetic field. Fig. 1 shows that there were two flexible magnetic abrasive brush
formed on each pole of magnet. Finishing was done when rotatory motion was provided to workpiece due help of
lathe machine.

Fig. 1. Schematic diagram of cylindrical surface-MAF process setup [25]

 Rajneesh Kumar Singh et al./ Materials Today: Proceedings 5 (2018) 20455–20463 20457

2.2 Internal surface finishing by using MAF process

To free internal surface of cylindrical surface tube from surface irregularities and impurities, Shinmura et al.
[26] developed the internal MAF process using direct current electromagnet. Fig. 2 shows plan of direct current
magnetic abrasive set-up in which fixed pole system was used. When current was flown into electromagnet, DC
magnetic field was produced which attracted magnetic abrasive magnetic particles into the finishing zone and
generating normal magnetic finishing force at inner surface of work piece. Smoothing of inner part of tube was done
by giving high rotational motion to tube.

Fig. 2. Schematic diagram of internal surface-MAF process setup [26]

2.3 Plane surface finishing by using MAF process

Further Singh et al. [28] had designed a flat-faced electromagnet for producing direct current magnetic field for
finish plane work piece surfaces. Fig. 3 shows, modification that had been done by author. In this set-up,
electromagnet was designed in such a way that its middle part was acted as north poles and external shell acted as
South Pole. When electromagnet was stimulated by DC power source, magnetic field was generated at the middle
pole and it return to the external pole without much of flux leakage. This electromagnet design produced strong
magnetic field at the middle and weak magnetic field at external shell.

Fig. 3. Schematic diagram of plane surface-MAF process setup [28]

20458 Rajneesh Kumar Singh et al./ Materials Today: Proceedings 5 (2018) 20455–20463

3. Experimental and Simulated Investigation of Response Outcomes

3.1 Impact of process parameters on surface finish

Surface finish is most desirable measure in the production field of new product. It is necessary to achieve high
dimensional accuracy for the proper assembly of the product and to improve the surface quality it must be free from
all kind of surface defects. To keep in mind the above factors, Jain et al. [10] did experimental study on cylindrical
bar using magnetic abrasive particle which was semi-bounded in nature. He took iron powder of mesh 300, alumina
of 600 mesh and added servo-pin oil which act as binder. The main finding was that material removal was directly
depended on higher circumferential speed and lower working gap. In case of surface roughness, it was depended on
higher circumferential speed; too. Further advancement was made by Singh et al. [29] by introducing pulsed direct
current magnetic abrasive finishing. They made magnetic abrasive brush more flexible by feeding pulsed direct
current. By doing this there was generation of stirring effect, through it more fresh abrasive particles were available
to the surface of workpiece and producing better surface finish. They showed that for longer formation of abrasive
brush, electromagnet was kept at maximum duty cycle pulsed current. Jain et al. [11] contributed further by
extending their work on pulsed magnetic abrasive finishing. They developed an empirical model to find out effect of
duty cycle and pulse-on time on percentage reduction in the surface roughness value, force ratio, normal magnetic &
cutting force. Their major finding; at constant on-time, %ΔRa rises with decline in duty cycle because FMAB got
more time to break due to increase in off-time. But for constant duty cycle, %ΔRa rises with rise in on-time because
strength of FMAB increases with more magnetization and it also increase off-time that results in the partial
disintegration of FMAB due to demagnetization.
To enhance concertation of magnetic flux in working gap following researchers had modified MAF set-up. Im
et al. [9] modified MAF set-up by adding yoke-part made of SS41 steel in permanent magnet (Fe-Nd-B) to
concentrate magnetic flux in working gap. They used diamond paste as abrasive & grinding fluid as binder with iron
powder as magnetic particle in their experiment. Major emphasis of study was to check the micro-diameter &
weight of STS 304 cylindrical work piece. Roundness was enhanced much in starting phase of machining because
unevenness was rapidly removed during that period like in case of surface roughness. But on roundness; impact of
abrasive size was remaining alike regardless of its size. To enhance magnetic flux in non-ferrous materials such as
aluminium, Givi et al. [5] introduced a new mechanism. In this, magnetic abrasive particles were placed behind the
aluminum plate that acts as work piece. Work piece was placed in between the magnet and FMAB. The FMAB
applied pressure on the backside of the work piece and the grains of FMAB penetrate more into the work piece
surface. Experimental outcome indicated that No. of cycles & machining gap were the most influential parameters
that had impact on surface roughness change.
Design of experiment plays very important role for systematic performance of experiment and contribution of
optimization cannot be undermine either, because for finding out optimal process parameters which effect
performance parameters. For improving the result of magnetic abrasive finishing Singh et al. [30] applied response
surface methodology (RSM)and ANOVA in their experimental study. They performed experiment on steel alloy
using unbounded magnetic abrasive particles. Their focus was to establish a relationship between No. of cycles with
surface roughness for diverse current value. ANOVA indicated that magnetic flux density & working gap were most
significant parameter trailed by mesh size of abrasive & No. of cycles. Later Singh et al. [32] used RSM to find out
contribution of sintered MAPs on surface finish of brass tube in internal MAF process. They revealed that material
removal rate and % improvement of surface finish was not entirely depended on individual contribution of input
process parameters, but it depended on interaction between magnetic flux & rotational speed, mesh size & rotational
speed and finally magnetic flux & mesh size for surface finish. While for material removal interaction between mesh
size & rotational speed and magnetic flux & quantity of abrasive. Most recently Shadab et al. [1] designed
experiment by applying taguchi L9 orthogonal array to find out influential process parameters which contribute in
enhancement of response of MAF process. Emphasis was laid on to find basic characteristic of sintered MAPs. In
this type of MAPs, abrasive particles (Al2O3) stack on the base metal matrix (iron powder) which eventually
improve quality of it. Optimized result showed that surface roughness was depend on input voltage, working gap,
rotational speed and abrasive mesh size. Voltage was most significant parameter which affected surface finish.
Theoretical analysis had been done by Jayswal et al. [13] by establishing Galerkin’s finite element model. In
their investigation, distribution of magnetic force on workpiece had been found. They did modelling and coding of
magnetic forces, material removal & surface roughness by using Fortran 90 programming language. Their model
 Rajneesh Kumar Singh et al./ Materials Today: Proceedings 5 (2018) 20455–20463 20459

predicted less material was removed from workpiece surface due to indentation and rotation of magnetic abrasive
particles. Further Judal [14] made progress by developing FEM model for cylindrical-magnetic abrasive finishing
for predicting behaviour of surface roughness & material removal. His focus was to assess dispersal of magnetic
forces on surface of workpiece. He developed MATLAB code based on mathematical modelling for validating
results. Simulated results very well predicted saturation effect of surface roughness as it presents in case of
experimental results. Newest advancement in this area had been done by Pashmforoush et al. [23]; they applied
extended finite element method (X-FEM) to study mechanism of material removal of brittle material i.e. BK7
Optical glass using magnetic abrasive process. Their technique had well simulated crack initiation and propagation
then conventional FEM method. They calculated normal force by using Ansoft maxwel model and then X-FEM
modelling was implemented to simulate the indentation and sliding process of abrasive.
3.2 Impact of process parameters on finishing magnetic forces

Magnetic forces play vital role in finishing performance of MAF process. There are two magnetic forces which are
present in MAF process, first is Normal magnetic force which is responsible for indentation and other is Tangential
cutting force for micro-chipping. Both have great influence on material removal and surface texture. To understand
the behaviour of these magnetic forces in MAF process, Mori et al. [18] had described basic mechanism of magnetic
abrasive finishing using stainless steel which was magnetic neutral material. They proposed that Magnetic abrasive
brush was formed due to interaction between magnetization energy, repulsion energy and tension energy. And
magnetic field produced normal force that pushed abrasive brush on material surface was responsible for
indentation.
To explain behaviour of magnetic forces Singh et al. [31] developed resistance force dynamometer for analysis
of forces. Their investigation revealed that normal magnetic force and tangential cutting force were, mainly
responsible for response performance of MAF. Interaction of voltage and working gap were important measure
because at higher voltage and lower working gap, strength of brush was more leading to more penetration which
degrade surface quality. To heighten magnetic forces in MAF process, Mulik et al. [19] fabricated four poles
electromagnet system with alternate north and south poles, for enhancing surface quality in least production time.
They showed that voltage didn’t affect surface roughness alone, but it interaction between voltage and rpm of
electromagnet. This interaction was described as, at lesser rpm surface roughness was directly proportional to
voltage because normal magnetic force upsurges with upsurge in magnetic flux density that depend on voltage and
there was rise in indentation to work piece.

3.3 Impact of process parameters on surface temperature

To check surface temperature of workpiece is very important for surface integrity. On higher temperature
chemical composition of surface can be changed, surface become more prone to corrosion and strain hardening can
impart mechanical failure. To study these effect, Komanduri et al. [7] were first men who worked in this area and
employed transient and steady-state thermal model in magnetic-field assisted finishing of ceramics. They derived a
thermal model from the standard moving heat theory of Jaeger. By applying this thermal model, they retrieved a
general solution for steady state and transient for moving disk heat source with parabolic distribution of heat
intensity. This model substantially calculated flash temperature produced during machining and flash time at
interaction point.
The first experimental approach to investigate effect of surface temperature in magnetic abrasive finishing
were began by Mulik et al. [20]; they found that there was good connection between surface temperature rise and
performance responses. They completed experiment on ultrasonic-assisted MAF & temperature analysis was done
for different processing settings. They validated their experimental results by comparing it with temperature
empirical model using Buckingham’s dimensional analysis. Key finding of their study were that, temperature
directly depends on voltage, weight of abrasive particles and pulse on time. On higher voltage, magnetic brush
become stiffer and more normal force produces more indentation on workpiece surface which increases temperature.
Finite element method is a powerful technique which help in modelling of surface temperature rise in the MAF
process. Kumar et al. [16] had derived mathematical solution using Finite element method (FEM) to forecast
temperature rise in the workpiece. They established SIMU-MAF software using MATLAB software for the
estimating the temperature rise on the work piece surface. Conclusion was that, temperature elevated due to
escalation in magnetic particle velocity & magnetic potential. For slighter temperature inside the workpiece, value
of magnetic flux density and tool rpm must be suitably selected.
20460 Rajneesh Kumar Singh et al./ Materials Today: Proceedings 5 (2018) 20455–20463

4. Recent Advancement in MAF- Process

4.1 Surface modification of advanced material using MAF process

Latest development had taken place in this field is that, this process is very versatile enough that it could be
used finishing non-magnetic material, super-alloys and advanced ceramics. Kala et al. [15] had implemented ultra-
sonic MAF for polishing copper alloy. The aim of study was to compare test results obtained by MAF and UAMAF
for various output parameters. Test results revealed that UAMAF had better finishing ability than MAF. Because
UAMAF had induced ultra-sonic vibration to MAPs and tendency of collision of MAPs with peak of roughness in
workpiece had increased. Finally, they suggested that this process could be used by electronic industries to finish
non-magnetic materials. To finish advance material which have high hardness and wear resistance such as Tungsten,
Sihag et al. [27] employed MAF process. They used chemical agent H2O2 to oxidize surface of tungsten. Study
showed that, with rise in percentage of concertation of H2O2 there was rise in surface roughness because H2O2 made
material softer. Finishing was done by combined effect of chemical oxidation and magnetic forces.
Heng et al. [6] investigated effect of carbon nano-tube (CNT) while finishing circular magnesium alloy using
MAF. Aim of their investigation was to compare finishing effect of CNT mixed MAPs with non-CNT mixed MAPs.
Conclusion was made that CNT mixed MAPs gave excellent surface finish as compared to non-CNT mixed MAPs
because CNT had superior mechanical properties such as high temperature, elasticity, high strength and it was light
weight. Rampal et al. [24] study impact of different kinds of magnetic abrasive particles on brass tube using MAF
process. The objective was to find out, most suitable types of MAPs for finishing workpiece. Special type of
adhesive bond MAPs was manufactured by adding adhesive to mixture of Iron & SiC. Investigation showed that
finishing performance of sintered MAPs was best followed by adhesive MAPs. The poorest performance was of
simply mixed MAPs. For finishing of zirconia ceramics, Park et al. [22] had used MAF process. Zirconia was bio-
ceramics which had extensive use in medical field because it had favourable mechanical and chemical properties. In
their approach, ultra-high-speed machining was developed by using brushless motor which had spindle speed of
35000 rpm. Finally, it was established that ultra- high-speed machining based MAF was efficiently reduced the
diameter and improve surface roughness. Diameter reduction was directly depended on rotational speed, greater the
speed better diameter reduction.

4.2 Process monitoring to improve response performance of MAF process

In near years, many online monitoring and process controlling system were implemented to boost process
performance of MAF process. For accomplishing it, Oh et al. [21] had developed ANN-predictive model by fusion
data for online monitoring set-up which shown in fig. 4, consisted of acoustic emission and force sensor. The
acoustic emission was formed by using transient elastic stress waves created within workpiece by quick release of
strain energy. The AE rms and count rate, along with AE spectrum were used to monitor the surface roughness.
Finally, signal from the AE and force sensor were processed and analysed.

Fig. 4. Schematic diagram of ANN-predictive model [21]

After that Hung et al. [8] had developed Fuzzy-nets predictive model for in-process prediction of MAF. By
utilizing five-step tactic rule bank, a five-layered fuzzy-nets model was built by applying the significant parameters
which was predicted by ANOVA. The test showed that model was 97% precise. Hence this system could further be
 Rajneesh Kumar Singh et al./ Materials Today: Proceedings 5 (2018) 20455–20463 20461

used to develop into adaptive control system. Further Ahn et al. [2] applied run-to-run regulating method for
effective supervisory of the process parameter which affects the surface roughness in the MAF. Run-to-run method
had form of discrete time process control in this specific kit process recipe was improved b/w equipment runs to
recompense for the process drift, large shifts & other errors to keep the outputs at the specific target values.

4.3 Employing alternating field to improve productivity of MAF process

In recent years, work had been carried out to produce magnetic field with help of alternating current which
provided excellent scattering effect in MAPs. Alternating current provide up-down movement to abrasive particle
and hence it increases utilization rate of MAPs which finally improved the surface finishing of material. To utilize
the above advantageous features of alternating current, Wu et al. [33] developed new finishing mechanism for
finishing brass tube. Their set-up consisted of alternating current electromagnet mounted on motor for providing
rotation. A tray was placed over poles of electromagnet and Workpiece was kept on it as shown in fig. 5. Tray
contained finishing fluid which was mixture water-oil soluble and electrolytic iron powder. They concluded that
using alternating current had enhanced surface quality of workpiece and MAPs had excellent stirring effect. Wu et
al. [34] extended their investigation by using low frequency alternating magnetic field. They gave emphasis on
finding significant process parameters namely current frequency, grinding fluid & poles rotation which were
dominating response parameters. Major findings were, size and amplitude of fluctuating finishing forces were
directly proportional to size of magnetic particles. Finishing fluid formed denser magnetic cluster to generate more
fluctuating finishing forces. Finally, frequency of alternating current had directly proportional to surface roughness
and material removal rate.

Fig. 5. Schematic diagram of alternating-MAF process setup [33]

Later, Wu et al. [35] simulated fluctuating finishing forces using Fourier transformation. Aim was to compare
finishing force produced by alternating magnetic field to direct magnetic field. Analysis showed that alternating
magnetic field produces higher finishing force which remove more material than direct magnetic field. At lower
frequency, alternating field had obtained smoother surface. Kumar et al. [17] used SUS-304 stainless steel pins to
modify the inner surface of brass tube. They fabricated indigenous alternating field MAF set-up which had
electromagnet with opposite N-S poles. Workpiece was placed between poles having variable AC frequency: 0.5Hz-
50Hz. Input parameters which were critical for surface modification was vibrational frequency of pins, finishing
time, working gap and rotational speed. At last, this process improved surface hardness and surface finish of brass
tube.

5. Conclusion
Magnetic abrasive finishing process had emerged as proficient finishing operation that enriches the surface
quality and surface texture of work piece surface. It had been extensively applied in industrial and medical sectors
that required part finish in microns. The surface roughness and material removal are two vital performance
parameters that depend on working gap and magnetic flux density. Stirring effect enhances performance magnetic
abrasive brush and improves surface finish. Pulsed-magnetic abrasive finishing process upsurges stirring and decline
the surface temperature of the surface of the work piece.
20462 Rajneesh Kumar Singh et al./ Materials Today: Proceedings 5 (2018) 20455–20463

Finite element analysis (FEM) was used for modelling and simulation of magnetic forces, surface roughness,
material removal and surface temperature of work piece surface. MAF process can be easily enhance the surface
properties if advanced material and ceramics. ANN based-online monitoring and Fuzzy-nets & Run-to-Run based
control system had been used to improve the performance and productivity of MAF. Alternating field MAF process
has emerged as powerful finishing process which is versatile enough to modify surface properties.

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