Magnetic Abrasive Finishing of cutting tools for high-speed machining of titanium alloys

This paper describes the Magnetic Abrasive Finishing (MAF) mechanism for cutting tools. While maintaining surface functionality and initial cutting edge radius, MAF improves tool surface roughness with minimal material removal. The magnetic particle brush is a critical factor, and the effects of the brush composition on the magnetic force and brush behavior are studied. The relationships between surface conditions of AlTiN-coated round tools, cutting forces, and wear characteristics were clarified by milling of Ti-6Al-4V alloys. The roughness of coated tools was improved by 50–60% without deteriorating the cutting edge radius, and the tool life was extended by 150%.