Abrasive flow machining (AFM) is a relatively new process with low material removal ratio fordeburring, removing recast layers and finishing industrial components with complex shapes among nonconventional machining processes. In this process, the finishing is handled by flowing the compositionof viscoelastic and abrasive particles on workpiece surface, under the pressure of piston. In thisresearch, the abrasive flow machining process of H13 tool steel by applying an external magnetic fieldaround the workpiece to improve the material removal ratio and surface roughness has been investigatedand the effect of magnetic field intensity, abrasive particles mesh and the hardness of workpiece as theinput parameters on the process outputs including surface roughness and material removal ratio wasstudied. Also, the regression model of MRR and surface roughness was developed and variance analysiswas performed. Results of experiments indicated that increase in abrasive-particles mesh leads todecrease in surface roughness and material removal ratio and increase in magnetic field intensity causesmaterial removal ratio to increase and surface roughness to decrease. Also, the material removal ratio isdecreased with increasing workpiece hardness and in the same condition better surface finish wasachieved in the case of harder workpiece.

In this study, a rotating magnetic field and ultrasonic vibrations are employed as an effective solution to address the challenges of the magnetorheological abrasive flow finishing (MRAFF) process. To achieve this goal, an industrial-scale MRAFF setup was first designed and fabricated. After preparing the magnetorheological polishing (MRP) fluid, a rotating magnetic field was applied, and ultrasonic vibrations were subsequently introduced perpendicular to the fluid flow direction onto the workpiece. To evaluate the performance of the proposed method, the influence of processing time on three key indicators—surface roughness ratio, finishing rate, and material removal rate—was investigated in 2024 aluminum alloy tubes. The results revealed that within the first 10 minutes of processing, not only did the surface roughness ratio decrease, but the finishing rate and material removal rate also increased. However, prolonging the process led to a resurgence in surface roughness due to the detrimental effects of abrasive particles. Microscopic images not only confirmed these findings but also demonstrated that under optimal conditions, the proposed method produced a uniform surface and reduced the internal tube roughness by up to 98%. Consequently, this method presents a promising and efficient solution for finishing and deburring internal surfaces, particularly in long tubular components.

In the current paper application of magnetic abrasive polishing process, on paramagnetic workpieces is investigated. A magnetic disc which comprises of six magnetic coils and is electrified with three phase AC current is used to perform the experiments. In the experimental setup various parameters including; rotational speed of abrasive pins, quantity of abrasive pins, working gap, abrasive pins' dimensions and process's time can be changed. Changing this parameters surface quality is investigated. Two kinds of workpieces with different mechanical properties are examined. It is observed that both increasing the rotational speed and using smaller pins improve final surface quality but the rotational speed has a sharper effect. There are optimum abrasive pins quantity and working gap in which the best surface quality is obtained. The results are similar for the both selected materials.

Magnetic abrasive finishing can be classified as a non-traditional super finishing method for finishing surfaces with different shapes and working materials like flat plates, shafts, bearings parts, screws, tubes and many other mechanical parts that need good surface finishing properties. MAF is effective in polishing, cleaning, deburring and burnishing metal parts. The most important parameter affecting the performance of this method, such as surface roughness, is the magnetic force. The magnetic force is obtained from a permanent Magnet or a DC magnet. In this article, the magnetic field strength, magnetic flux density and magnetic force in different states are studied using simulation with some finite element method software (Maxwell). The shapes of magnets, various sizes and the material of fixture are studied. The magnetic properties of the material of the work piece are simulated too. To verify the simulation results, the situation is also measured by a Gauss meter. The intensity of the magnetic field required for the micro chipping is obtained for different geometric shapes and various materials of work piece in the magnetic abrasive finishing process. The results show that increasing the distance from the magnet surface results in a decrease in the magnetic flux density and significance of the edge phenomenon effect. The effect of work piece material, work piece fixture material, and the interaction of them were is shown to be significant on magnetic flux density. To concentrate the magnetic abrasive powder in the polishing process of non-ferromagnetic parts, the ferromagnetic fixture for these parts can be provided.

Rotational abrasive flow machining process (RAFM) is one of the modern surface polishing processes where in the material removal in micro and nano sizes is performed by tiny abrasive particles. Rotational abrasive flow machining is very effective in finishing of complex internal and external surfaces. in comparison with other finishing methods. In this study, the rotational abrasive flow machining process has been investigated in polishing of AISI H 13 hot work steel. The main objectives of workpiece rotation was increasing the material removal rate and decreasing the surface roughness of workpiece. So the effects of rotational speed and hardness of workpiece and the mesh size of abrasive particles as input variables on the output parameters including surface roughness and material removal rate have been studied. The results showed that applying of rotational speed of workpiece leads to higher material removal rate and lower surface roughness. Furthermore, the material removal rate is decreased and surface roughness is improved by increasing the mesh size of abrasive particles. Also, increasing the hardness of workpiece leads to decreasing the material removal rate, and in similar cutting conditions, the surface of workpiece with more hardness is better polished in comparison with the surface of workpiece with lower hardness.

Ultrasonic Assisted Magnetic Abrasive Finishing (UAMAF) is the combination of magnetic abrasive finishing (MAF) and ultrasonic vibrations to finish the surfaces in nanometer scale. In this work, the experimental setup for UAMAF was prepared to finish inner surface of tube work piece. By using experimental setup, the effect of experimental parameters such as ultrasonic vibrations, mesh number, the type of abrasives (SiC and diamond) and finishing time has been investigated on the changes in the surface roughness of tube work piece. The experimental results showed that the use of ultrasonic vibrations has a significant effect on reducing the surface roughness. The changes in surface roughness increase with the mesh number from 90 to 800 and finishing time from 30s to 5 min. Among two types of abrasives, diamond showed the best performance in finishing. Optical microscopy images showed that the dominant finishing mechanism in MAF for coarse grains (with mesh size of 90 and 120) is two body and for fine grains (with mesh size of 220, 400 and 800) is three body. In UAMAF, for both of the coarse and fine grains the dominant finishing mechanism is three body.

To overcome the limitation of honing process, the present work proposes magnetic abrasive honing (MAH) process whereby abrasive stones are replaced by magnetic abrasives. This process is combination of magnetic abrasive finishing (MAF) and honing. MAF which is one of the finishing processes can improve the quality of work piece surface with various geometries, removing the chips in micrometer scale by magnetic field forces. This study set to apply longitudinal vibration to the tube work piece in MAF process, hence, this process is called MAH. The effects of rotary speed of work piece, cross-hatch angle, and mesh number were investigated on the surface roughness of AISI 304. Magnetic abrasives were combination of SiC particles as abrasives and iron particles as ferromagnetic particles in lubricant of SAE 40 oil. The results revealed that the longitudinal movement of work piece is effective on MAH, as the surface roughness decreased with increasing the cross-hatch angle. Surface roughness decreased with increase of rotary and mesh number. The major changes in surface roughness (58%) were obtained in cross-hatch angle of 45º rotary speed of 800 rpm and mesh size of 400. The microscopic picture showed that three-body wear mechanism is dominant for fine grits.

Super alloys generally are among the materials with poor machinability. The removal of metal contaminations, stains, and oxides can positively affect their performance. Magnetic Abrasive Finishing (MAF) is a method which uses a magnetic field to control the material removal. As another advantage, this method can be used to polish materials such assuperalloys which have high strength and special conditions. In this paper, we investigated the magnetic abrasive finishing of nickel-base super alloy Inconel 718. Since the process is highly influenced by several effective parameters, in this study we evaluated the effects of some of these parameters such as percentage of abrasive particles, gap, rotational speed, feed rate, and the relationship between size of abrasive particles and the reduction of average surface roughness. Using Minitab software package the experiments were designed based on a statistical method. Response surface method was used as the design of the experiment. The regression equation governing the process was extracted through the assessment of effective parameters and analysis of variance. In addition, the optimum conditions of MAF were also extracted. Analysis of the outputs of MAF process experiments on IN718 revealed that gap, weight percent of abrasive particles, feed rate, rotational speed, and size of abrasive particles were the factors that affected the level of changes in surface roughness. The distance between the magnet and the work piece surface, i.e. the gap, is the most important parameter which affects the changes in surface roughness. The surface roughness can decrease up to 62% through setting up the process at its optimum state i.e. in a rotational speed of 1453 rpm, feed rate of 10 mm/min, percentage of abrasive particles equal to 17.87%, size of particles equal to #1200, and gap size of 1 mm. There is a discrepancy of 13% between this prediction and the predicted value by the regression model. With mounting a magnet with a different pole beneath the work piece, magnetic flux density increases up to 35%.

Drilling is the most widely used process for producing holes through the manufacturing parts. Drilling, as well as other machining processes, produce undesired raised material on both entrance and exit edges. The raised material caused by plastic flow is defined as burr, which is necessary to be removed for critical and precise part. In this work, magnetic abrasive deburring (MAD) was used to investigate the deburring performance of stainless steel. Firstly preliminary simulations were carried out by Maxwell software to determine appropriate MAD tool. Then, influence of MAD variables such as height of gap, mesh number and rotational speed were studied on burr height variation. Results indicated that mesh number of abrasive particles has the dominate effect in burr removal of stainless steel plate by this process.

Surface finishing is one of the most significant steps in industries which are engaged with surface quality. Finishing by magnetic field is a new method of surface finishing. In this process, machining is executed in mechanical way and semi-homogeneous abrasive slurry performs finishing of surfaces. Needed force to grind surfaces is made by magnetic field. Therefor this method is considered as an advanced machining method. One of application of advanced machining methods is working in situation which conventional methods are not applicable. Nowadays helical and spiral parts have an important position in industry. This result in more attention about manufacturing and finishing of parts. This mechanism is used to finish helical ball screw in CNC machine using magnetic field created by Nd-Fe-B permanent magnet. In executed experiments four parameters which affected on surface quality were investigated. These parameters included feed rate, particles size and amount of ferromagnetic particles. The effect of most parameters was positive and caused to improve surface quality, but generally each parameter had an optimum amount in which by reaching this amount, reducing in efficiency and surface quality was observed. Also, some parameters such as cutting speed had lower effect. The initial specimen had surface roughness of 1.017 µm and the best resultant surface quality was 0.325 µm.