Study on ultra-precision magnetic abrasive finishing process using low frequency alternating magnetic field

•We investigated magnetic field distribution in processing region.•Magnetic cluster can produce a fluctuating finishing force in alternating magnetic field.•Oily grinding fluid is more applicable to this process.•Few nanometer finish surface can be obtained by this process.

We proposed a new ultra-precision magnetic abrasive finishing (MAF) process using low frequency alternating magnetic field in this paper. Magnetic cluster themselves may produce the up and down movement change under alternating magnetic force. The movement may not only promote the dispersion of micro-magnetic particles, but also improve stirring effect and cross-cutting effects of the abrasives, achieving circulation and update to ensure the stability of grinding tools. This process is considered to be able to efficiently apply in ultra-precision finishing of plane and complicated micro-surfaces. In this study, we investigated the effects of alternating magnetic field on magnetic field distribution, finishing force and abrasive behavior. Furthermore, a set of experimental devices have been designed for finishing SUS304 stainless steel plate. The present work is aimed at understanding finishing particularity of this process and studying impacts of important process parameters namely grinding fluid, rotational speed of magnetic pole, current frequency on change in finish surface and material removal. Experimental results indicate that the process can realize ultra-precision finishing of plane by using oily grinding fluid. In the present research, the surface roughness of SUS304 stainless steel plate was improved from 240.24 nm to 4.38 nm by this process.