Experimental Study of Magnetic Particle Grinding on Slender Tube Surfaces Based on Combined Magnetic Poles

JIN Yuhang; YANG Haiji; TANG Jiabin; HAN Bin; SHEN Qiushi; XU Xiaotong

doi:10.16490/j.cnki.issn.1001-3660.2025.20.014

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Surface Technology ›› 2025, Vol. 54 ›› Issue (20) : 196-206. DOI: 10.16490/j.cnki.issn.1001-3660.2025.20.014

Precision and Ultra-precision Machining

Experimental Study of Magnetic Particle Grinding on Slender Tube Surfaces Based on Combined Magnetic Poles

JIN Yuhang^1,2, YANG Haiji^1,2,*, TANG Jiabin^1,2, HAN Bin^1,2, SHEN Qiushi^1,2, XU Xiaotong^1,2

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Abstract

Magnetic particle grinding is an advanced precision machining technology that enables flexible processing of workpieces with excellent adaptability. However, uneven magnetic field distribution and low magnetic flux density during magnetic particle grinding often result in inconsistent finishing and low efficiency. The work aims to optimize the external magnetic field by arranging magnetic poles based on a single sector-shaped magnetic pole with dimensions of φ35 mm×10 mm× 40 mm and a sector angle of 40° as the fundamental unit, so as to address issues such as low magnetic flux density and uneven grinding.
The magnetic field distribution of three pole arrangements—combined magnetic poles with equal volume, Halbach array with opposite polarity, and Halbach array with like polarity—was simulated with Maxwell finite element analysis software. The Halbach array with like polarity exhibited superior performance, with a peak magnetic flux density of 1 032.92 mT and a stable fluctuation around 1 000 mT across all positions, ensuring uniform force distribution on magnetic particles. The force distribution on the inner surface of the tube and the motion state of particles were analyzed with EDEM discrete element simulation software. Under the Halbach array with like polarity, the inner surface exhibited the highest grinding pressure, normal force, and tangential force, with significant fluctuations and intense particle motion, which facilitated particle rolling and renewal. Particle adsorption was uniform across the entire inner surface, with a consistent number of active particles, resulting in high grinding efficiency and excellent uniformity.
The test workpiece was a slender SUS304 tube with dimensions of φ8 mm×2 mm×700 mm. Two measurement sections were cut from the tube at positions 20 cm apart. A mixture of 80-mesh magnetic particles and an appropriate amount of grinding fluid was used as the grinding medium. The machining gap was set to 2 mm, and experiments were conducted through three magnetic pole arrangements. The tube rotation speed was 600 r/min, and the feed rate of the magnetic pole device was 2 mm/s. The surface morphology of the tube was observed with a super-depth microscope before and after the experiments. Surface roughness values were measured with a JB-100C horizontal precision roughness tester, and roughness profiles were recorded. The initial surface roughness was approximately Ra 3 μm.
Based on experimental results of the three magnetic pole arrangements, the Halbach array with like polarity yielded the best results, significantly improving the inner surface quality of the tube. Initial defects were nearly eliminated, deep scratches were completely removed, and surface roughness profile became smoother. After grinding with the Halbach array with like polarity, the surface roughness values at two positions decreased from Ra 3.045 μm and Ra 3.083 μm to Ra 0.165 μm and Ra 0.175 μm, respectively, achieving a reduction rate of over 94%. This performance surpassed that of the Halbach array with opposite polarity and the combined magnetic poles with equal volume.
By modifying the magnetic pole arrangement, the magnetic flux density can be effectively enhanced, and the uniformity of the magnetic field distribution can be improved, thereby increasing the grinding efficiency and consistency of the inner tube surface.

Key words

magnetic particle grinding / composite magnetic poles / magnetic field distribution characteristics / grinding uniformity / grinding efficiency / surface roughness value

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JIN Yuhang, YANG Haiji, TANG Jiabin, HAN Bin, SHEN Qiushi, XU Xiaotong. Experimental Study of Magnetic Particle Grinding on Slender Tube Surfaces Based on Combined Magnetic Poles[J]. Surface Technology. 2025, 54(20): 196-206 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.20.014

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Funding

Youth Project of the Basic Research Project of Higher Education Institutions of Liaoning Provincial Department of Education (JYTQN2023243); General Project of Liaoning Provincial Department of Education (LJ212510146002)