Characteristics of magnetic elastic abrasive particles and their effect on tool passivation

Magnetic elastic abrasive particles are a new type of particle that combines the characteristics of magnetic abrasive particles and elastic abrasive particles by embedding magnetic media and abrasive particles in a specific proportion into a flexible polymer to create particles with a specific shape. The magneto-elastic abrasive particles were prepared using liquid silica gel as the matrix, alumina particles (Al₂O₃) or silicon carbide particles (SiC) as the abrasive phase, and iron particles as the magnetic particle phase. A representative microunit model of magnetic elastic abrasive particles is created using 3DMAX software. The finite element software ABAQUS analyzes the micromechanical properties of magnetic elastic abrasive particles with silicon carbide (SiC) and alumina (Al₂O₃) particles as the abrasive phase, respectively. Secondly, based on the characteristics of double-disk magnetic force passivation of magnetic elastic abrasive particles, a method is proposed to predict the life of magnetic elastic abrasive particles by predicting the roughness of the tool edge. The impact of particle size and abrasive phase on the wear and life of magnetic elastic abrasive particles is studied experimentally. Finally, the magnetic field force is analyzed and a mathematical model for material removal for magnetic elastic abrasive particles is established based on the mixing phase’s characteristics. The effects of particle size and abrasive degree on material removal volume and the influence of magnetic elastic abrasive particle size on tool passivation are studied experimentally. A comparison is made with the vertical rotary passivation method. The superiority of the magnetic flexible abrasive particle passivation method is confirmed by examining the passivated tool’s edge profile, surface roughness, and service life.