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The present research focuses on the development of modified electrochemical magnetic abrasive finishing set up to reduce the issues like abrasive washing and electrolytic short circuit. Orientation of magnetic poles and electrode at 90° angular distances improved the finishing performance. Experiments were performed using a central composite design of response surface methodology on a modified setup. The finishing performance of the process is analyzed using the analysis of variance during the finishing of SS 304. The influence of the working gap, concentration of NaNo 3 , electrolyte current, and workpiece rotational speed on the surface roughness and material removal is investigated. An experimental model is also obtained for the surface roughness and material removal. Multi-response optimization has been performed, and optimal values for SR and MR are obtained as 0.001 µm Ra and 57.673 mg, respectively. The confirmation test was conducted at an optimal point and validated the model, which proves the capability of the ECMAF process.

Development and experimentation of modified electro-chemical magnetic abrasive finishing