Taqi, S., Shather, S., Hamdan, W. (2025). Reducing the surface roughness of curvature surfaces by electrical discharge machining with magnetic abrasive finishing. , 43(12), 1208-1228. doi: 10.30684/etj.2025.162757.1985
Shahad A. Taqi; Saad K. Shather; Wisam K. Hamdan. "Reducing the surface roughness of curvature surfaces by electrical discharge machining with magnetic abrasive finishing". , 43, 12, 2025, 1208-1228. doi: 10.30684/etj.2025.162757.1985
Taqi, S., Shather, S., Hamdan, W. (2025). 'Reducing the surface roughness of curvature surfaces by electrical discharge machining with magnetic abrasive finishing', , 43(12), pp. 1208-1228. doi: 10.30684/etj.2025.162757.1985
Taqi, S., Shather, S., Hamdan, W. Reducing the surface roughness of curvature surfaces by electrical discharge machining with magnetic abrasive finishing. , 2025; 43(12): 1208-1228. doi: 10.30684/etj.2025.162757.1985

Reducing the surface roughness of curvature surfaces by electrical discharge machining with magnetic abrasive finishing

Engineering and Technology Journal
Volume 43, Issue 12, December 2025, Pages 1208-1228    PDF (2.14 M)
Document Type: Research Paper
DOI: 10.30684/etj.2025.162757.1985
Authors
Shahad A. Taqi* 1; Saad K. Shather1; Wisam K. Hamdan2
1College of Production Engineering and Metallurgy, University of Technology-Iraq, Alsina’a street, 10066 Baghdad, Iraq.
2College of Biomedicine, University of Technology-Iraq, Alsina’a street, 10066 Baghdad, Iraq.
Abstract
This study presents an integrated work that combines unconventional machining and finishing techniques for complex geometric models. A Taguchi design investigated three electrical-discharge parameters—electric current, pulse duration, and gap—each at three levels; a multi-objective optimization matrix was then used to select the optimal conditions. The geometric models were designed using SolidWorks software and machined on a CNC machine to ensure maximum accuracy in the resulting samples. The samples were finished using the magnetic abrasive finishing technique, where the particle mixture was developed as a hybrid blend of two types of abrasive particles, tungsten carbide (WC) and silicon carbide (SiC). Among the electrical discharge machining factors, electric current showed the highest influence, yielding a maximum metal removal rate of 25.1024 mm³/min at Ip = 42 A, Tn = 300 µs, gap = 8 mm, and the minimum roughness of 11.6674 µm at Ip = 24 A, Tn = 150 µs, gap = 5 mm. The magnetic abrasive finishing stage substantially improved the surface quality of the complex models, reducing roughness from 11.9169 µm to about 4.29 µm, equivalent to a 64.02% reduction. Within finishing, feed rate was the most influential variable, followed by spindle speed, while particle size had the least effect. Overall, the combined methodology improves process performance and post-process surface quality for complex geometries while identifying the dominant parameters that govern material removal and roughness outcomes.

Highlights
  • Complex 3D models were designed in SolidWorks and fabricated using CNC machining.
  • EDM was applied to study the effects of current, pulse on-time, and gap on MRR and roughness.
  • Current was found to be the most dominant factor affecting MRR and surface roughness.
  • GRA optimization identified the best condition for balancing the removal rate and surface finish.
  • Magnetic abrasive finishing improved surface roughness by up to 64.02% with hybrid abrasives.
Keywords
Electrical discharge machining; Magnetic abrasive finishing; Complex shapes; Hybrid particles; Improved surface roughness
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