Experimental Investigation into MRR of Polished Zinc Plate with Ultrasonic Vibrations Using Single Pole Magnetic Abrasive Finishing Process

Year : 2026 | Volume : 14 | Special Issue 01 | Page : 428 438
    By

    Arsh Siddiqui,

  • Mragank Sharma,

  • Kheelraj Pandey,

  • Ashwani Sharma,

  1. UG scholar, Department of Mechanical Engineering, Amity University , Lucknow, Campus, Uttar Pradesh, India
  2. Assistant Professor, Department of Mechanical Engineering, Amity University , Lucknow, Campus, Uttar Pradesh, India
  3. Assistant Professor, Department of Mechanical Engineering, Amity University , Lucknow, Campus, Uttar Pradesh, India
  4. Assistant Professor, Department of Mechanical Engineering, Amity University , Lucknow, Campus, Uttar Pradesh, India

Abstract

The present research examines the material removal rate (MRR) in finishing zinc plates on the experimental framework called Single Pole Magnetic Abrasive Finishing Process (SPMAFP) by inducing ultrasonic vibrations. By means of a Flexible Magnetic Abrasive Brush (FMAB) composed of 40% alumina and 60% iron elements, the investigation estimates the effect of key process parameters on surface finishing excellence. An L-16 factorial study design was applied to examine the FMAB speed, working gap, feed rate, and pulse-on time effect on MRR. Statistical examination shows that higher FMAB speed and smaller working gap significantly increases the material removal by increasing magnetic flux concentration and abrasive indentation force. The optimal parameters are 1500 RPM speed, 6mm working gap, 5.5mm/s feed rate, and 7.3 minutes pulse-on time, yielding an MRR of 9.8 mg/min. SEM analysis confirmed the procedure successfully eliminated the surface deficiencies, producing a smooth surface roughness (SR). Ultrasonic vibrations increase the MRR by abrasive particle agitation thus reducing the frictional resistance at the contact surface. The maximum MRR attained without ultrasonic vibration was 6.4 mg/min, but ultrasonic-assisted trials got 9.8 mg/min, indicating a 53% increase in material removal rate. Experimental results closely matched theoretical predictions, validating effectiveness of the chosen process parameters.

Keywords: Flexible magnetic abrasive brush (FMAB), Magnetic abrasive finishing process (MAFP), Material removal rate (MRR), Single-pole magnetic abrasive finishing process (SPMAFP), Surface roughness (SR)

[This article belongs to Special Issue under section in Journal of Polymer & Composites (jopc)]

How to cite this article:
Arsh Siddiqui, Mragank Sharma, Kheelraj Pandey, Ashwani Sharma. Experimental Investigation into MRR of Polished Zinc Plate with Ultrasonic Vibrations Using Single Pole Magnetic Abrasive Finishing Process. Journal of Polymer & Composites. 2026; 14(01):428-438.
How to cite this URL:
Arsh Siddiqui, Mragank Sharma, Kheelraj Pandey, Ashwani Sharma. Experimental Investigation into MRR of Polished Zinc Plate with Ultrasonic Vibrations Using Single Pole Magnetic Abrasive Finishing Process. Journal of Polymer & Composites. 2026; 14(01):428-438. Available from: https://journals.stmjournals.com/jopc/article=2026/view=237339


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Special Issue Subscription Original Research
Volume 14
Special Issue 01
Received 25/09/2025
Accepted 13/11/2025
Published 21/02/2026
Publication Time 149 Days
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