Research on grinding force modelling of spherical alumina magnetic abrasive powder

Magnetic abrasive finishing (MAF) is an effective surface refinement technology. However, its material removal mechanism remains elusive, stalling its advancement. This study utilized a spherical alumina magnetic abrasive powder (MAP) produced through atomization process to research on the grinding force of the MAF. A model was formulated to predict the grinding force in MAF, considering magnetic conductivity, MAP distribution, abrasive shape, and indentation depth. According to contact theory, the interaction between single abrasive and the workpiece is analyzed. A genetic algorithm was incorporated into the model to determine the unknown parameters of the normal grinding force. The friction coefficient between the alumina abrasives and the workpiece was deduced using the least squares technique. The model's predictions align with experimental data, providing deeper insights into the material removal behavior of the spherical alumina MAPs in MAF. The study delved into the material removal mechanism of the spherical MAPs in relation to surface characteristics. After using this MAP in the MAF process, surfaces exhibited micro-plowing.