Abstract
In this work a new process, namely ultrasonic-assisted magnetic abrasive finishing (UAMAF), has been conceived. This technique integrates the use of ultrasonic vibrations and a magnetic abrasive finishing (MAF) process to finish surfaces to nanometre order within a short time span. This paper is focused on the development of the UAMAF setup. The performed experimental studies were planned using response surface methodology and the Taguchi method and change in surface roughness (ΔRa) and material removal rate (MRR) were considered as the responses, respectively. The experimental results showed that the UAMAF process yielded better finishing characteristics compared to those obtained using the MAF process. The surface roughness value obtained by UAMAF were as low as 22 nm within 80 s on a hardened AISI 52100 steel workpiece. Analysis of experimental data showed that the percentage change in surface roughness (ΔRa) was highly influenced by mesh number followed by percentage weight of abrasive, rotation speed of the electromagnet, and voltage. Weight of abrasives was found to be the most significant process parameter affecting the MRR. Optimum process parameters were also obtained to maximize ΔRa at minimum MRR.