Modeling and Simulation of Cylindrical Electrochemical Magnetic Abrasive Machining Process

Cylindrical Electrochemical Magnetic Abrasive Machining (C-EMAM) is an advanced abrasion-based hybrid machining process that constitutes magnetic abrasive machining and electrochemical dissolution. During the C-EMAM process, a large amount of material is removed from the peaks of the surface irregularities under the simultaneous effect of electrochemical dissolution, abrasion and abrasion-passivation synergism. This article presents the mathematical modeling for material removal and surface roughness during the C-EMAM process. Magnetic potential distribution between the two magnetic poles in which a cylindrical workpiece was placed was calculated using the finite element method. It was further used to find the forces acting on the ferromagnetic particles at contact surfaces. An empirical relation has been also developed considering the effect of electrochemical dissolution and abrasion-passivation synergism based on experiments conducted on a self-developed C-EMAM setup. Finally, a surface roughness model was developed by considering the total volume of material removed with the assumption of a triangular surface profile. The simulated results for material removal and surface roughness were validated using self-conducted experimental results. The computed results were found to be in good agreement with experimental observations.