Fine Finishing of Metal Matrix Composite Plate with Magnetic Abrasives

In order to overcome the need of harder tools required for difficult-to-cut materials, the technology has advanced from traditional finishing processes to precision and ultra-precision processes based on non-traditional techniques. The limitations of traditional finishing processes need to be eliminated. This led to the development of loose abrasives-based finishing processes wherein low mechanical forces are used to finish the surfaces. Magnetic abrasive finishing (MAF) process is one of the non-traditional finishing processes. The diamond-based sintered magnetic abrasives are used to finish round plate of MMC. The MMC plate is prepared by mixing SiC abrasive and aluminium by stir casting method. Three process parameters (magnetic field density, rotational speed and abrasive/lubricant ratio) are taken as input variables. A well-known design of experiment approach “response surface methodology” is employed for the conduct and analysis of experimental work. The rotational speed taken in this work is bidirectional for ensuring proper dressing of abrasives. The combination of high magnetic flux density, average rotational speed and less lubricant caused better results, and the best surface finish of 1.12 μm is achieved.