Characteristics of ultra-high-speed micro processing machines using magnetic abrasive machining methods

Magnetic abrasive machining (MAM) is a machining technique in which magnetic fields are used to control abrasive tools during the machining process of a material. Due to the development of engineering technologies, various properties such as surface accuracy, dimensional accuracy, and lightweight materials are required in current engineering applications. This study proposes the development of a new ultra-high-speed magnetic abrasive machining technique with the goal of improving the dimensional accuracy, surface accuracy and weight of a material. Moreover, to reduce machining time, this machining method was developed using an ultra-high-speed spindle, capable of rotating up to 80000 rpm. In this study, Ti-6Al-4V (Eli) bars were used as cylindrical workpieces and were machined via magnetic abrasive machining processes with an ultra-high-speed spindle. Results showed that improvements in the diameter and quantity of removed material were the highest at an operational speed of 80000 rpm, followed by 40000 rpm, 20000 rpm and 2000 rpm. The initial surface roughness of 0.21 μm Ra was improved to 0.04 μm Ra at 80000 rpm for 75 seconds. To evaluate the machining capabilities of the ultra-high-speed MAM process in terms of surface roughness, a descriptive statistical method was used. Precision weight data, laser scan micrometer data, roundness data, surface roughness data, and AFM images of the machined surface were recorded and studied.