Abstract: Advanced finishing processes are essential in modern industry to achieve the surface integrity required for high-strength materials used in aerospace and medical applications.
This project presents the design and fabrication of an Electro Magnetic Abrasive Finishing (EMAF) machine, a non-conventional finishing system capable of achieving "mirror-like" surface quality. The system utilizes a suspension tank where an electromagnetic field drives abrasive particles, across the workpiece to precisely remove material from complex geometries.
To ensure precise control, the machine integrates an Arduino-based microcontroller platform to manage system operations and motor outputs. The performance of the EMAF process was evaluated by analyzing the influence of key parameters, including rotating speed, feed rate, depth of cut, and the number of passes, on the surface roughness of aluminum and wood workpieces.
Experimental results demonstrate that systematic calibration of these parameters significantly improves fatigue strength and wear resistance by eliminating surface irregularities. This project aims to provide a high-precision, cost-effective, and scalable finishing solution for industries where traditional grinding methods fail to meet stringent design requirements. Hassan El-Hofny et al [1]focused on the material removal rate (MRR) and the physics of the abrasive-workpiece interface, establishing the "Flexible Magnetic Abrasive Brush" (FMAB) as a multipoint cutting tool P.C. Pandey and H.S. Shah et al [2] categorized EMAF as a vital super-finishing process. Recent reviews confirm its necessity for medical implants and aerospace components where "mirror-like" finishes are required to improve fatigue life.

Keywords: Abrasive Machining, Electromagnetic Machining, Surface roughness, non-conventional finishing process.

Downloads: | DOI: 10.17148/IARJSET.2026.13407