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<p>Magnetic abrasive finishing (MAF) is a non-contact processing method that utilizes magnetic fields and is widely applied in aerospace and other high-tech industries. However, due to the difficulty in quantifying the process of this type of discrete particle processing method, problems such as unclear processing mechanisms and unpredictable processing results arise. This study investigates the machining mechanism of MAF and its effect on the mechanical properties of 7075-T6 aluminum alloy. By integrating multi-field coupling simulations, such as the discrete element method, with experimental performance characterization, the MAF process is quantitatively analyzed, thereby enabling the prediction of post-processing mechanical properties. Through computational fluid dynamics (CFD)-discrete element method (DEM) coupling simulations and finite element analysis, combined with experimental results, the processing mechanism of MAF was thoroughly investigated, and the effective processing form of MAF was clarified. The residual stress, grain size, microhardness and fatigue life after processing were studied, discussed and analyzed in combination with theory, and verified in the finite element simulation. The results indicate that the improved mechanical properties of the 7075-T6 aluminum alloy samples after MAF are primarily attributed to the synergistic effects of the introduction of residual compressive stress, the improvement of microhardness, and grain refinement. The residual stress-affected zone extends to a depth of approximately 200&#xa0;μm. Grain refinement and plastic deformation are confined to a shallower depth of about 30&#xa0;μm, with the average grain size decreasing from 49.33&#xa0;μm to 38.89&#xa0;μm and a concurrent weakening of the crystallographic texture. Microhardness increased by up to 24.6%, and this enhancement conformed to the Hall-Petch relationship. Fatigue tests showed that the average fatigue life of the processed samples increased to 122,162 cycles, which is approximately 188% higher than that of the original samples. This research provides analytical insights into the processing mechanisms of discrete abrasive particle methods such as MAF, and lays the foundation for the development of “process-performance” collaborative control in finishing processes.</p>

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Research on the strengthening effect and mechanism of magnetic abrasive finishing on the mechanical properties of 7075-T6 aluminum alloy

  • 期刊论文

  • 发表日期：

    2026年8月4日

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  • Haoyi Wang,
  • Jun Ying,
  • Haiji Yang,
  • Shuangkun Dong,
  • Yue Zhang,
  • Bing Han

摘要

Magnetic abrasive finishing (MAF) is a non-contact processing method that utilizes magnetic fields and is widely applied in aerospace and other high-tech industries. However, due to the difficulty in quantifying the process of this type of discrete particle processing method, problems such as unclear processing mechanisms and unpredictable processing results arise. This study investigates the machining mechanism of MAF and its effect on the mechanical properties of 7075-T6 aluminum alloy. By integrating multi-field coupling simulations, such as the discrete element method, with experimental performance characterization, the MAF process is quantitatively analyzed, thereby enabling the prediction of post-processing mechanical properties. Through computational fluid dynamics (CFD)-discrete element method (DEM) coupling simulations and finite element analysis, combined with experimental results, the processing mechanism of MAF was thoroughly investigated, and the effective processing form of MAF was clarified. The residual stress, grain size, microhardness and fatigue life after processing were studied, discussed and analyzed in combination with theory, and verified in the finite element simulation. The results indicate that the improved mechanical properties of the 7075-T6 aluminum alloy samples after MAF are primarily attributed to the synergistic effects of the introduction of residual compressive stress, the improvement of microhardness, and grain refinement. The residual stress-affected zone extends to a depth of approximately 200 μm. Grain refinement and plastic deformation are confined to a shallower depth of about 30 μm, with the average grain size decreasing from 49.33 μm to 38.89 μm and a concurrent weakening of the crystallographic texture. Microhardness increased by up to 24.6%, and this enhancement conformed to the Hall-Petch relationship. Fatigue tests showed that the average fatigue life of the processed samples increased to 122,162 cycles, which is approximately 188% higher than that of the original samples. This research provides analytical insights into the processing mechanisms of discrete abrasive particle methods such as MAF, and lays the foundation for the development of “process-performance” collaborative control in finishing processes.