Thermal Interaction Analysis Between Flexible Magnetic Abrasive Brush and Aluminium Alloy During Single-Pole MAF

Year : 2026 | Volume : 14 | Special Issue 01 | Page : 1906 1918
    By

    Chandan Kumar Jha,

  • Kheelraj Pandey,

  • Vineet Srivastava,

  • Ashwani Sharma,

  • Gaurav Raj Pandey,

  1. Research scholar, Department of Mechanical Engineering, Amity University, Lucknow, Uttar Pradesh, India
  2. Assistant Professor, Department of Mechanical Engineering, Amity University, Lucknow, Uttar Pradesh, India
  3. Associate Professor, Department of Mechanical Engineering, Thaper University, Patiala, Punjab, India
  4. Assistant Professor, Department of Mechanical Engineering, Amity University, Lucknow, Punjab, India
  5. PG Scholar, Department of Mechanical Engineering, Amity University, Lucknow, Uttar Pradesh, India

Abstract

Magnetic Abrasive Finishing (MAF) is a precision surface‐finishing approach that employs magnetic abrasive particles (MAPs) within a managed magnetic field to eliminate micro-level material and enhance surface condition. In the finishing process, the friction created between the workpiece and the flexible magnetic abrasive brush (FMAB) leads to heat accumulation, which may badly affect the surface integrity. This study focuses on investigating the temperature distribution at the FMAB–workpiece interface to decrease thermal effects and enhance finishing performance. The influence of key constraints—polishing speed (500–1500 RPM), feed rate (1.5–5.5 mm/s), working gap (6–7 mm), and Keller’s etchant concentration (2.5–7.3% wt./wt.)—was studied. Before finishing, the aluminium alloy samples were pre-etched with Keller’s reagent to improve processing efficiency. An L16 factorial experimental design was implemented, and interface temperatures were measured at 10-minute intervals using an infrared thermometer. The study focuses on the combined effects of FMAB rotational speed, working gap, and feed rate on interface temperature. Results express that optimising these process parameters extensively reduces thermal load. The best possible conditions identified—1500 RPM FMAB speed, 6 mm working gap, 1.5 mm/s feed rate, and 7.3% wt./wt. Keller’s concentration produced a minimum contact temperature of 28.41°C, contributing to improved machining efficiency and surface quality.

Keywords: Work Brush Temperature (WBT), Magnetic Abrasive Finishing (MAF), Chemical Machining Process (CMP), Magnetic Abrasive Particles (MAP), Single-pole Magnetic Abrasive Finishing (SPMAF), Keller’s reagent, Flexible Magnetic Abrasive Brush (FMAB), Analysis of Variance (ANOVA).

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

How to cite this article:
Chandan Kumar Jha, Kheelraj Pandey, Vineet Srivastava, Ashwani Sharma, Gaurav Raj Pandey. Thermal Interaction Analysis Between Flexible Magnetic Abrasive Brush and Aluminium Alloy During Single-Pole MAF. Journal of Polymer & Composites. 2026; 14(01):1906-1918.
How to cite this URL:
Chandan Kumar Jha, Kheelraj Pandey, Vineet Srivastava, Ashwani Sharma, Gaurav Raj Pandey. Thermal Interaction Analysis Between Flexible Magnetic Abrasive Brush and Aluminium Alloy During Single-Pole MAF. Journal of Polymer & Composites. 2026; 14(01):1906-1918. Available from: https://journals.stmjournals.com/jopc/article=2026/view=239186


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Special Issue Subscription Review Article
Volume 14
Special Issue 01
Received 11/12/2025
Accepted 05/01/2026
Published 25/03/2026
Publication Time 104 Days
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