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Journal of Polymer & Composites Review Article Special issue

Thermal Interaction Analysis Between Flexible Magnetic Abrasive Brush and Aluminium Alloy During Single-Pole MAF

  1. Chandan Kumar Jha Department of Mechanical Engineering, Amity University, Lucknow
  2. Kheelraj Pandey Department of Mechanical Engineering, Amity University, Lucknow
  3. Vineet Srivastava Department of Mechanical Engineering, Thaper University, Patiala
  4. Ashwani Sharma Department of Mechanical Engineering, Amity University, Lucknow
  5. Gaurav Raj Pandey Department of Mechanical Engineering, Amity University, Lucknow

Abstract

Magnetic Abrasive Finishing (MAF) is a precision surface‐finishing approach that employs magnetic abrasive particles (MAPs) within a managed magnetic field to eliminate micro-level material and enhance surface condition. In the finishing process, the friction created between the workpiece and the flexible magnetic abrasive brush (FMAB) leads to heat accumulation, which may badly affect the surface integrity. This study focuses on investigating the temperature distribution at the FMAB–workpiece interface to decrease thermal effects and enhance finishing performance. The influence of key constraints—polishing speed (500–1500 RPM), feed rate (1.5–5.5 mm/s), working gap (6–7 mm), and Keller’s etchant concentration (2.5–7.3% wt./wt.)—was studied. Before finishing, the aluminium alloy samples were pre-etched with Keller’s reagent to improve processing efficiency. An L16 factorial experimental design was implemented, and interface temperatures were measured at 10-minute intervals using an infrared thermometer. The study focuses on the combined effects of FMAB rotational speed, working gap, and feed rate on interface temperature. Results express that optimising these process parameters extensively reduces thermal load. The best possible conditions identified—1500 RPM FMAB speed, 6 mm working gap, 1.5 mm/s feed rate, and 7.3% wt./wt. Keller’s concentration produced a minimum contact temperature of 28.41°C, contributing to improved machining efficiency and surface quality.

Keywords

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