Magnetic field-assisted finishing of blind holes: experimental validation and optimization

To improve the internal surface quality of blind holes, a novel magnetic field-assited finishing (MAF) device using N52 permanent magnets is developed based on Magnetic Brush Theory and blind-hole structures. This study firstly applies the novel device for MAF of blind-hole interiors. The optimal distance between the permanent magnet and the part is determined through simulations, based on a double-helical magnetic field adjustment device. The effects of parameters are investigated using single-factor experiments, followed by orthogonal experiments to optimize parameters. Furthermore, experiments with different materials and blind-hole dimensions are conducted to validate the adaptability of the proposed method, while dimensional measurements assess geometric intergrity. The results demonstrate that the proposed device reduces surface asperities by more than 32.89% while maintaining dimensional integrity. The optimal parameters are a rotational speed of 500 r/min, abrasive size of 40 mesh, and polishing time of 1 min.