Enhanced magnetic abrasive finishing of Ti-6Al-4V using shear thickening fluids additives

The available magnetic field assisted finishing process is considered as the critical stage for improvement of workpiece surface quality. This paper aims to investigate the key quality performance of an enhanced magnetic abrasive finishing in achieving nanolevel finish on Ti-6Al-4V workpieces with initial micrometer surface roughness values. The finishing media, combining the intelligent shear thickening fluids (STFs), carbonyl iron particles and SiC particles, is developed. Finishing experiments for Ti-6Al-4V workpieces are conducted using an established platform, aiming to investigate the effects of varying STFs concentration, working gap, feed rate and spindle rotational speed. It is observed from the experimental results that the developed finishing media is effective for surface finishing comparing to the finishing media without STFs. The surface roughness of 54 nm was achieved from the initial value of 1.17 mu m, which improved by over 95%, under the experimental conditions of 0.8 mm working gap, 15000 mm/min feed rate, 900 rpm spindle rotational speed and 15 wt% STFs. Surface observations showed that a smooth surface without obvious scratches was obtained.