Nd-Fe-B-based permanent magnets are essential for a wide range of industrial, military, and consumer applications. Machining processes are crucial to their production, as they ensure precise dimensions, accurate shapes, and high-quality surface integrity, while also maintaining tight tolerances. However, despite their importance, the scientific literature lacks comprehensive information on the machining of Nd-Fe-B magnets, especially regarding the surface formation mechanisms involved in processes including wire electrical discharge machining (WEDM). In this study, Nd-Fe-B samples were first machined using WEDM under two finishing conditions (Finishing A and B) and then subjected to electropolishing using a nitric acid solution in denatured alcohol. The process involved varying the current density and processing time. The surface quality was analyzed by measuring surface morphology and surface roughness (Ra and Rq), and the material removal rate (MRR) was calculated. The results obtained showed that electropolishing significantly improved surface smoothness, especially at higher current densities and longer processing times. In this case, increasing the current density to 1.0 A/cm2 and extending the processing time to 10 min led to a notable reduction in surface roughness, with the best results observed under Finishing A. Additionally, the material removal rate increased with both current density and time, the surface morphology from WED-machining in Finishing B enhances material removal during electropolishing. The MRR was significantly influenced by current density and processing time, with Finishing B enabling a more aggressive removal rate, making it effective for optimal surface refinement in Nd-Fe-B samples. Thus, applying the electropolishing process after wire electrical discharge machining is a potential process to be applied to manufacturing of Nd-Fe-B magnets.

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Effect of the Wire Electrical Discharge Machining and Electropolishing on Surface Quality of the Nd-Fe-B Magnet

  • Erick Cardoso Costa,
  • Gustavo Sorgetz,
  • Natalie Souza Heinz,
  • Beatriz Cardoso Santos,
  • Fabio Antonio Xavier

摘要

Nd-Fe-B-based permanent magnets are essential for a wide range of industrial, military, and consumer applications. Machining processes are crucial to their production, as they ensure precise dimensions, accurate shapes, and high-quality surface integrity, while also maintaining tight tolerances. However, despite their importance, the scientific literature lacks comprehensive information on the machining of Nd-Fe-B magnets, especially regarding the surface formation mechanisms involved in processes including wire electrical discharge machining (WEDM). In this study, Nd-Fe-B samples were first machined using WEDM under two finishing conditions (Finishing A and B) and then subjected to electropolishing using a nitric acid solution in denatured alcohol. The process involved varying the current density and processing time. The surface quality was analyzed by measuring surface morphology and surface roughness (Ra and Rq), and the material removal rate (MRR) was calculated. The results obtained showed that electropolishing significantly improved surface smoothness, especially at higher current densities and longer processing times. In this case, increasing the current density to 1.0 A/cm2 and extending the processing time to 10 min led to a notable reduction in surface roughness, with the best results observed under Finishing A. Additionally, the material removal rate increased with both current density and time, the surface morphology from WED-machining in Finishing B enhances material removal during electropolishing. The MRR was significantly influenced by current density and processing time, with Finishing B enabling a more aggressive removal rate, making it effective for optimal surface refinement in Nd-Fe-B samples. Thus, applying the electropolishing process after wire electrical discharge machining is a potential process to be applied to manufacturing of Nd-Fe-B magnets.