Influence of Magnetic Abrasive Finishing Process Parameters on Surface Roughness of SAE 52100 Steel Using a Hemisphere Pole Geometry Electromagnet

International Journal of Mechanical Engineering

© 2025 by SSRG - IJME Journal

Volume 12 Issue 4

Year of Publication : 2025

Authors : Rajendra E. Kalhapure, Mayank Shekhar, Ravindra R. Navthar, Prashant N. Nagare

10.14445/23488360/IJME-V12I4P102

How to Cite?

Rajendra E. Kalhapure, Mayank Shekhar, Ravindra R. Navthar, Prashant N. Nagare, "Influence of Magnetic Abrasive Finishing Process Parameters on Surface Roughness of SAE 52100 Steel Using a Hemisphere Pole Geometry Electromagnet," SSRG International Journal of Mechanical Engineering, vol. 12,  no. 4, pp. 11-19, 2025. Crossref, https://doi.org/10.14445/23488360/IJME-V12I4P102

Abstract:

Finishing is the last stage of the manufacturing of jobs that demand the utmost quality with regard to shape, precision, and surface integrity. Fine-finishing is a process that improves the surface of the workpiece, enhancing its functional and quality attributes. The automotive sector requires precise finishing to enhance the performance, appearance, and longevity of its components. 52100 bearing steel is widely utilized in the production of critical components for various bearings and other applications. However, conventional finishing methods can be difficult to apply when creating components of diverse shapes and sizes. To address this, advanced fine machining and finishing techniques are being employed. One such method is magnetic abrasive finishing (MAbF), a precision technique that produces outstanding quality components. This process utilizes a flexible magnetic abrasive brush (FMAB) guided by a magnetic field to achieve the desired finish. Typically, the magnetic abrasives used in MAbF consist of two key components: ferromagnetic materials and abrasives, which work in tandem. In this study, 52100 steel bars undergo fine polishing using an MAbF technique, with various process parameters being examined. Aluminum oxide (Al2O3) serves as the abrasive, while a hemisphere-shaped DC electromagnet is employed for the finishing process. Key variables can be adjusted to achieve optimal surface finishes, including magnetic flux density, component rotation speed, and the ratio of abrasive to ferrous powder in the mixer. The effectiveness of the process is influenced by factors such as the abrasive particle content in the mixing ratio, the speed of the workpiece, and the input DC power source that determines the magnetic flux density. The results indicate that increasing the rotation speed and DC voltage enhances the surface roughness of the 52100 bearing steel rods. Specifically, experiments reveal that improvements in rotation speed and DC voltage can lead to a 57% increase in the maximum enhancement of surface roughness.

Keywords:

Magnetic abrasives finishing, Hemisphere electromagnet, Flexible magnetic abrasives-brush, Magnetic abrasives particles.

References:

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