Material removal model of magnetoelastic abrasive particles in dual-disk magnetic cutting edge preparation

Magnetoelastic abrasive particles are new composite particles formed by abrasive-phase alumina particles, magnetic-medium-phase iron particles, and a polymer matrix in a specific proportion. Abrasive particles exhibit both viscoelasticity and magnetic conductivity. In this study, we propose a preparation method for magnetoelastic abrasive particles and build up a magnetoelastic abrasive dual-disk magnetic edge preparation equipment. Based on the characteristics of the abrasive particles and the dual-disk magnetic edge preparation, a mathematical model of material removal by a single magnetoelastic abrasive particle is established considering the effects of multiple factors, such as the volume fraction of the constituent particles, abrasive particle size, disk rotational speed, and disk spacing. According to the number of active alumina abrasive particles acting on the tool surface and the movement trajectory of the magnetoelastic abrasive particles, we establish a mathematical model of material removal by magnetoelastic abrasive particles. We combine this model with tool edge preparation experiments to study the influence of the magnetoelastic abrasive particle size, disk spacing, and disk rotational speed on the surface roughness of the cutting edge and the amount of material removed from the cutting edge. The results show that the largest (smallest) discrepancy between the theoretical and experimental values for the amount of removed material is 15.8% (3.3%). After the edge preparation, the surface gloss of the tool is improved, and the surface roughness is significantly reduced by 54.72%, which indicates that the introduction of magnetoelastic abrasive particles in the dual-disk tool edge preparation equipment can effectively improve the surface quality of the tool. These results are of great scientific and engineering significance for the application of magnetoelastic abrasive particles to tool edge preparation as well as for promoting the advancement of magnetic high-efficiency machining and magnetic finishing machining.