Surface Finishing of Aluminum Alloys-3003 At Nano-Level Through use of Box-Behnken Experimental Design Methods by Magnetic Field-Assisted Finishing Processes

Abstract

This research investigates the application of the Magnetic field-assisted finishing process (MFAFP) by using a media of Magnetorheological fluid for nano-level surface finishing's ability to improve the practical and surface quality of materials is becoming more widely acknowledged. Surface roughness is reduced to the nanoscale by the MFAF process, which can enhance component performance. Traditional finishing methods cannot provide the necessary level of smoothness, which might cause problems with both performance and appearance. The novelty is that the nano-level surface finishing of aluminium alloy 3003 is by MFAF processes using the Box-Behnken Design (BBD) method. The process is designed to target a smooth surface at the nanoscale. The system parameter modifies the tool rotational speed, finishing time, and workpiece-tool gap to evaluate their impact on the surface finish. Initially, the surface roughness was found to be 380 nm. After the MFAF processes, its decrease of surface roughness to less than 15 nanometer was confirmed by measurements made using an optical profilometer and atomic force microscopy (AFM), and an even and flawless finish was revealed by using scanning electron microscopy (SEM) insights into surface morphology. The results demonstrated that the percentage change in surface roughness (%∆Ra) from (BBD) predicted responses was 93.37% value and from experimental value (%∆Ra) was found to be 96.0%, error found to be 2.74%, and the MFAF process significantly improved the surface quality of the aluminum alloy-3003. This study highlights that aluminium component performance and surface quality can be enhanced by using MFAF processes.