Materials Today: Proceedings 49 (2022) 390–396

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Materials Today: Proceedings

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Experimental investigation of electro-chemical magnetic abrasive

finishing of SS 304 workpiece
Ashokkumar R. Chaudhari ⇑, Kesarabhai B. Judal
Mechanical Engineering Department, Government Engineering College, Palanpur, India

a r t i c l e i n f o a b s t r a c t

Article history: Industry demands Nano level of surface finishing and development of advanced material makes finishing
Available online 6 March 2021 difficult to attain for modern grinding industry. The Electro-Chemical Magnetic Abrasive Finishing
(ECMAF) is an advanced abrasion based finishing process used to finish very hard material with superior
Keywords: surface finishing. In ECMAF, soft film generated by electro-chemical dissolution (ECD) on the workpiece is
Electro-chemical magnetic abrasive removed by gentle finishing force of micron size abrasive particles of Magnetic abrasive Finishing (MAF).
finishing In this process, the material is removed in the form of microchips without sub surface damage. This paper
Unbonded magnetic abrasive particles
presents the experimental investigation of SS 304 workpiece using indigenously newly developed ECMAF
Surface finishing
Taguchi methodology
set up that eliminates the problem of washing of abrasive particles by electrolyte from the working gap.
The Un-bonded Magnetic Abrasive Particles (UMAPs) are prepared by mechanical mixture of ferromag-
netic particles and abrasive particles. The experiment is designed using L25 orthogonal array of
Taguchi Methodology and effect of working gap, workpiece rotational speed, electrolytic flow rate and
electrolytic current on the Surface Roughness (SR) and Material Removal (MR) is studied. The result is
analyzed using ANOVA and found the working gap to be the most significant process parameter followed
by workpiece rotational speed and electrolytic current for SR while the working gap is found to be most
the significant process parameter for MR.
Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Advancement in Materials, Manufacturing and Energy Engineering (ICAMME-2021).

1. Introduction Magneto Rheological Abrasive Flow Finishing, Magnetic Float Pol-

ishing, MAF and ECMAF [23].
Now-a-days, industrial technological development leads to the It is also observed that SS 304 is widely used in the industries
need of Nanometer level of surface finishing of high functional like food and beverages, chemical, pharmaceutical, bio medical
components, such as construction of bearings, high speed shafts, industries where aseptic and hygienic is very important[4]. These
nozzles, wear parts of pumps, ball of the valves, mold inserts, sur- can be obtained by maintaining corrosion free surface. For this,
gical tools etc. At the same time use of advanced materials in aero- component’s ideal surface finishing up to Nano level is required.
space, defense, robotics, pharmaceuticals, biomedical, automobiles This level of surface finishing cannot be achieved by using conven-
and nuclear industries is increases day by day[12]. The traditional tional machining process. It is required to use advanced finishing
machining processes are become inefficient to finish advanced processes which can finish very hard material to Nano level of sur-
materials with high level of surface finishing and this makes it face finish.
more challenging for manufacturing industries and modern grind- ECMAF is an advanced finishing process, constituent of abrasion
ing industries. The advanced manufacturing processes can be alter- based process MAF and chemical reaction based ECD process,
natives for the traditional process to overcome this problem. These which produce synergic effect and give Nano level of surface finish-
processes are Abrasive Flow Machining, Chemo-Mechanical Polish- ing. The MAF process mainly consists of permanent magnets or
ing, Electro-Emission Machining, Magneto Rheological Finishing, electromagnets, magnetic poles and MAPs and the ECD mainly
consists of Electrodes, Electrolyte supply system and DC power
supply [4]. When surface is exposed to ECD, electrolysis process
⇑ Corresponding author. takes place and it makes material softer irrespective of its level
E-mail address: arc.uvp@gmail.com (A.R. Chaudhari). of hardness and produce thin micron soft film which has hardness

https://doi.org/10.1016/j.matpr.2021.02.295
2214-7853/Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Advancement in Materials, Manufacturing and Energy
Engineering (ICAMME-2021).
A.R. Chaudhari and K.B. Judal Materials Today: Proceedings 49 (2022) 390–396

less than the parent material [5]. This thin soft film can easily be fully by designing unique tool and obtained mirror like surface fin-
removed by micron abrasive particles in successive MAF process. ishing. By using L18 orthogonal array of Taguchi method of design,
In MAF, Electromagnet or permanent magnets provide the mag- they had experiment various process parameters such as working
netic field which is transferred to magnetic poles. The gap between gap, tool revolution speed, abrasives type and lubricants grades.
the workpiece and the magnetic pole is filled with UMAPs which El-Taweel [20] developed mathematical model based on Response
are prepared by mechanical mixing of ferromagnetic and abrasive Surface Methodology (RSM) by applying electro-chemical turning
particles [4]. The ferromagnetic particles are magnetized and with MAF and found significant improvement by 33% and 143%
transfer the force to the adjacent abrasive particles. The abrasive in surface finishing and MR respectively compared to only applying
particles, which are in contact with workpiece, work as a cutting electro-chemical turning. Judal and yadava [6] had experimented
tool and remove the material in the form of micro chips. The MAPs AISI-420 material using cylindrical electro-chemical magnetic
are of two types, unbonded and bonded [6]. The unbonded MAPs abrasive set up and found the improvement in SR because of cross
are prepared by simple mechanical mixing of ferromagnetic parti- hash pattern generated on surface by the frequency of longitudinal
cles such as iron powder, steel grit etc. and the abrasive particles vibration. They had also experimented AISI304 cylindrical work-
such as boron carbide, silicon carbide, aluminum oxide, diamond piece by varying workpiece rotational speed, current to electro-
powder etc. The bonded MAPs are prepared by sintering process. magnet, electrolytic current and frequency of vibration. They
Using MAF, T Shinmura [7] investigated influence of magnetic found that rotational speed and electrolytic current have consider-
abrasive particle size on stock removal and surface finishing of able effect on the both SR and MR [21]. Tailor et al. [5] explored the
cylindrical SS 41 bar. They found that MR and SR increases as fer- ECD process and found the enhancement of performance of ECD
romagnetic particle and abrasive particle size increases. It is very process in terms of surface finish and MR using additional source
important to choose size of MAPs to attain lower SR and higher of energy like magnetic force, vibration etc. Farwaha et al. [22]
MR. Amnieh et al. [8] developed MAF set up and designed taper designed and developed ultrasonic assisted MAF combined with
magnetic tool to finish internal spiral grooves of aluminum cylin- electrolytic process and experimented SS 316 L cylindrical work-
der. They had experiment various process parameters including piece which shows better results than conventional processes.
rotational speed of tool, abrasive mesh number and finishing time Judal and Yadava [23] developed model using FEM by considering
using design of full factorial method. Tian et al. [9] used multiple total volume of material removed with assumption of triangular
pole-tip finishing tool to finish Ti-6Al-4 V on MAF and found surface profile and obtained mathematical equation to predict
improved capabilities of newly developed finishing tool. Kala MR and SR for Cylindrical electrochemical magnetic abrasive
et al. [10] finished planar paramagnetic workpiece using two oppo- machining of nonmagnetic steel. Bai et al. [24] applied dry
site magnetic pole position arrangement. They made comparative mechanical-electrochemical polishing to finish selective laser
study of copper alloy and stainless steel and found different effect melted surface of SS 316 L and reduced surface roughness from 7
of process parameter on each material workpiece because of differ- um to 0.8 um after processing 6 hrs. From the literature review it
ent individual mechanical properties. Wang and lee [11]used new is observed that still the ECMAF process is in the laboratory stage
magnetic abrasive medium as SiC in silicone gel mixed with steel and the effect of various process parameters is required explore
grit to resolve the efficiency and recycling problem of MAF and fin- and to check the applicability to ECMAF for various material and
ished SKD11 HRC 60 tool steel by considering various process applications and makes this process to use commercially.
parameters to found the effect on MR and SR. Wu et al. [12] used In the present work, ECMAF is applied to finish 10 mm diameter
low frequency alternating magnetic field and produced alternating shaft of SS 304 workpiece which is used in the pump of food pro-
magnetic force to finish SUS 304 workpiece and obtained higher cessing industry. The Experiments were conducted on indige-
finishing efficiency. They found the effect of magnetic field, grind- nously developed ECMAF attachment installed on CNC machine.
ing fluid type, magnetic pole speed, and current frequency on sur- Experiments are designed using Taguchi Methodology and results
face finishing. During the finishing of inconel 718, Guo et al. [13] are analyzed using ANOVA.
found that due to the inability of carbonyl powder carrier to hold
large SiC or Al2O3 particles during the rotational motion of the
magnetic roller tools, large particles size abrasives have lower 2. Experimental set up
MR as well as polishing force than small particles size abrasives.
Fan et al. [14] used shear thickening fluid to develop newer finish- Few researchers had developed cylindrical ECMAF set up and
ing media and experimented MAF. They found enhanced perfor- performed experimentation. They observed that while finishing
mance of MAF using shear thickening fluid concentrations of the cylindrical workpiece, electrolyte falls on the workpiece from
15 wt%. Qin et al. [15] prepared CBN/Fe-based spherical magnetic the top and passes from the working gap on either side of the
abrasive by gas atomization with rapid solidification and investi- workpiece and washes away the abrasive particles from the work-
gated bonding microstructure using scanning electron microscope ing gap as shown in Fig. 1 (a). This is because in UMAPs, abrasives
and found abrasive has better grinding performance. Wani et al. are not bonded to ferromagnetic particles and are washed away by
[16] developed FEM model for a new hybrid process; magnetic the electrolyte passing from the working gap. So finishing effect
abrasive flow finishing by combining the features of abrasive flow becomes unstable when UMAPs are used. This affects the efficiency
finishing and magnetic abrasive finishing to found the magnetic of the magnetic abrasion. This problem can be eliminated by inno-
potential distribution in the magnetic abrasive brush formed dur- vative design of set up. In the present study, the ECMAF set up is
ing finishing action and developed model is used to evaluate designed, developed and successfully applied to improve the per-
machining pressure, surface finish and material removal. Jayswal formance of the process by eliminating above stated problem asso-
et al. [17] performed theoretical investigation of MAF and proposed ciated with the cylindrical ECMAF set up.
model for material removal and surface roughness accounting for The setup is designed as shown in Fig. 1 (b). Orientation of the
micro-cutting by considering a uniform surface profile without sta- magnetic pole is changed to prevent the washing of abrasive from
tistical distribution. Yan et al. [18] proposed hybrid machining pro- the magnetic field. In this design, magnetic pole are reoriented and
cess, electrolytic magnetic abrasive finishing (EMAF) constituent of positioned at 900 pole position and provided one side of ‘O’ ring
MAF and electrolytic dissolution processes. They concluded that while copper electrode is provided on the another side at 450 on
EMAF gives better surface finishing than only MAF is applied. Lin ‘O’ ring. During the finishing, electrolytes falls on the workpiece
et al. [19] finished free form surface of SUS 304 material success- and flow on the same side and then directly fall in the collector
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A.R. Chaudhari and K.B. Judal Materials Today: Proceedings 49 (2022) 390–396

Fig. 1. Schematic diagram of ECMAF set up (a) having problem of washing of abrasive from working gap (b) with reorientation of pole position to eliminate problem of
washing of abrasive from the working gap.

tank without passing through working gap. This prevents the

washing of abrasives from the working gap and makes process
stable.
The ECMAF is mainly consists of magnets, magnetic poles, elec-
trolyte supply system, electrode and DC power supply system. 2D
diagram of ECMAF set is shown in Fig. 2.
The ECMAF set up is manufactured indigenously and attached
on CNC lathe machine as shown in photographic view in Fig. 3.
To obtain higher magnetic flux density, magnets are arranged at
900 pole position in the right part of the ‘O’ ring. SS 400 is used
as material of the magnetic pole which transfers the magnetic flux
density from magnate to working gap. Al6061 is used as material of
‘O’ ring to prevent leakage of magnetic flux. With the use of screws
provided on ‘O’ ring, working gap can be adjusted and these screws
hold magnets tightly during working. The unbonded MAPs are
filled in the working gap. The unbounded MAPs are mixture of iron
and SiC Powders. Iron is utilized as ferromagnetic and SiC is as
abrasive particles in the present study. The properties of SS 304
are shown in Table 1. The workpiece is held in the chuck of the
CNC machine to provide rotational motion. Due to relative motion
Fig. 3. Photographic view of ECMAF set up.
between the workpiece and unbonded MAPs, flexible magnetic
abrasive brush (FMAB) is formed and it works as multi point cut-

Fig. 2. 2D Diagram of ECMAF set up.

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A.R. Chaudhari and K.B. Judal Materials Today: Proceedings 49 (2022) 390–396

Table 1 is obtained as less than 0.05 and the workpiece rotational speed
SS 304 material properties. and electrolyte flow rate are found as non-significant parameters
Parameters Parameters Values as P values is obtained as greater than 0.1.
Tensile strength (Ultimate) 505 MPa
Hardness Brinell 123
Hardness Rockwell B 70 4.1. Process parameters optimization for SR
Density 8.0 g/cm3
Young’s Modulus of Elasticity 193-200GPa For optimization of process parameter to obtain minimum SR,
Poisson’s ratio 0.29 level of process parameters is selected at maximum value of signal
Thermal conductivity 16.2 W/(m.K)
Magnetic permeability 1.008
to noise ratio from the Table 7. The minimum SR is obtained at
level 2 (1 mm) of working gap, level 1 (10 lit./Hr.) of electrolytic
flow rate, level 1 (2 amp) of electrolytic current and level 1
(1000 rpm) of workpiece rotational speed. At these levels, pre-
ting tool. Electrode is positioned at 450 on left side of the ‘O’ ring.
dicted value of SR is obtained as 0.239 mm at 12.34 signal to noise
DC power supply is supply current to workpiece and copper elec-
ratio.
trode and workpiece work as anode and copper electrode cathode.
Electrolyte is supplied to electrode by electrolyte supply system.
The experimental conditions are shown in Table 2. 4.2. Process parameters optimization for MR

3. Design of experiment Process parameters are optimized to obtain maximum MR and

level of process parameters is selected at maximum value of signal
From the exhaustive literature review and the screening exper- to noise ratio from the Table 8. The maximum MR is obtained at
iments, critical process parameters are found which are very level 2 (1 mm) of working gap, level 2 (5 lit./ Hr.) of electrolytic
important to analyze and required to explore the effect of them flow rate, level 2 (5 amp) of electrolytic current and level 1
on the SR and MR. These parameters are working gap, rotational (2000 rpm) of workpiece rotational speed. At these levels, pre-
speed of workpiece, electrolytic flow rate and electrolytic current. dicted value of MR is obtained as 47.4 mg at 36.48 signal to noise
The L25 orthogonal array of Taguchi methodology is used to design ratio.
the experiment which gives complete information of experiment
with less effort by reducing number of run. The level of process 4.3. Effect of process parameters on SR
parameters is presented in Table 3. Based on pilot experimentation
on developed ECMAF set up, it was observed that 90% of SR reduc- Fig. 4 shows graph of the effect of the various process parame-
tion is takes place in initial 20 min. of finishing. Hence in present ters on the SR of the SS 304 workpiece. It is observed that as work-
work, the finishing experiments were conducted for 20 min. The ing gap is increased from 1 mm to 5 mm; SR is increases and
SR was measured using SURFTEST-SJ-410 SR tester. The initial decrement in the surface finishing. This may be due to higher
average SR (Ra) of the workpiece was 0.5 mm. working gap provides low magnetic flux density and lower mag-
netic force on the unbonded MAPs and due to this, MAPs rolls over
4. Results and discussion the peaks on the surface of workpiece without cutting the material
and that’s why increase in SR as working gap increases. As elec-
Obtained results have been shown in Table 4. The SR was mea- trolyte current is increases, it is observed that there is not much
sured at three different spot of the workpiece and average of them effect of electrolytic flow rate on SR. There are slight decreases in
is considered. SR as electrolyte flow rate is increase from 5 lit/hr. to 10 lit/hr.
The analysis of variance (ANOVA) is used with 95% confidence because of the increases in the electrolysis rate and complete
level of process parameters to analyze the experimental results. removal of the thin passive film by successive abrasion of MAF.
An ANOVA details is shown in the Table 5 and Table 6 for response After the increase of electrolyte flow rate from 10 lit/hr. to 15 lit/
parameters SR and MR respectively. hr., SR is started to increases because of more electrolysis take
For the SR, the working gap is found to be the most significant place and thick layer of passive film is generated on the work sur-
process parameters as their P value is smaller than 0.05. The sec- face and that layer is not completely removed by successive abra-
ond and third most significant parameters are found as workpiece sion process. After the increase of flow rate from 15 lit/hr. to 25 lit/
rotational speed and electrolytic current as their P values are less hr., SR is decreases because of the erosion is started by the ECD
than 0.05 while electrolyte flow rate is found non-significant process itself and it’s become predominant process and improve
parameter as P value is found greater than 0.1. For the MR, working the SR. As the electrolytic current is initially increases, there is
gap is found to be most significant process parameters as P values improvement in the SR because as electrolytic current is increases,
electrolysis rate is increases and thickness of passive film is an
increase which is completely removed by successive abrasion pro-
Table 2 cess. After the increase of electrolytic current from 2 amps, SR is
Experimental conditions.
starts to increases. This may because of high current produce very
Parameters Parameters conditions thick passive film which cannot be completely removed by abra-
Workpiece material SS 304 sion process. After increase in electrolytic current from 4 amps,
Workpiece size U 10 mm, L 100 mm there is improvement in SR because of ECD process become pre-
Magnet material and size NdFeB, 50 * 20 * 12.5 mm dominant. It is also observed that as workpiece rotational speed
Abrasive type and size SiC, 25 mm is increases initially from 500 RPM to 1000 RPM, SR is improving
Ferromagnetic material and size Iron powder, 180 mm
Mixing weight percentage of MAPs 30% SiC and 70% iron powder
because as RPM increases, surface finishing length per unit time
Type of Electrolyte NaNo3 is increases. After the increase in rotational speed from 1000
% Concentration of NaNo3 20 RPM, SR is increases. This is due to very much increase in centrifu-
Electrode Material Copper gal force on the abrasive particles, which reduce the abrasion force
Finishing length mm
and increase in SR.
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A.R. Chaudhari and K.B. Judal Materials Today: Proceedings 49 (2022) 390–396

Table 3
Level of process parameters.

Sr. No. Input Parameter Level

2 1 0 1 2
1 Working gap in mm 1 2 3 4 5
2 Workpiece rotational speed in rpm 500 1000 1500 2000 2500
3 Electrolyte flow rate in Lit/hr 5 10 15 20 25
4 Electrolytic current in Amp 1 2 3 4 5

Table 4
Design of Experiment and Result (Average SR of grounded workpiece is 0.5 mm).

Std Run Working Gap in mm Electrolyte Flow Rate in Lit./Hr. Electrolyte Current in Amp Workpiece Rotational Speed in RPM SR in mm MR in Milligram
23 1 5 5 5 2000 0.358 28
18 2 4 20 2 2500 0.341 14
1 3 1 5 1 500 0.292 34
11 4 3 25 2 2000 0.322 18
7 5 2 20 5 500 0.312 34
5 6 1 25 5 2500 0.291 41
15 7 3 20 1 1500 0.336 13
24 8 5 10 1 2500 0.365 21
22 9 5 25 4 1500 0.357 28
12 10 3 5 3 2500 0.356 17
21 11 5 20 3 1000 0.321 12
6 12 2 15 4 2500 0.362 30
17 13 4 15 1 2000 0.348 16
4 14 1 20 4 2000 0.321 32
16 15 4 10 5 1500 0.334 23
9 16 2 5 2 1500 0.324 26
25 17 5 15 2 500 0.343 7
14 18 3 15 5 1000 0.336 31
10 19 2 10 3 2000 0.347 34
13 20 3 10 4 500 0.334 14
3 21 1 15 3 1500 0.307 38
8 22 2 25 1 1000 0.287 22
19 23 4 25 3 500 0.345 8
20 24 4 5 4 1000 0.332 28
2 25 1 10 2 1000 0.231 34

Table 5
ANOVA details for response parameter SR.

Source Sum of Squares df Mean Square F-value p-value % contribution

Model 0.0201 16 0.0013 8.58 0.0022
Working Gap 0.0111 4 0.0028 18.96 0.0004 52.11
Electolyte Flow Rate 0.0012 4 0.0003 2.04 0.1814 5.63
Electrolyte Current 0.0024 4 0.0006 4.13 0.0419 11.27
Workpiece Rotational Speed 0.0054 4 0.0013 9.19 0.0044 25.35
Residual 0.0012 8 0.0001 5.64
Cor Total 0.0213 24

Table 6
ANOVA details for response parameter MR.

Source Sum of Squares df Mean Square F-value p-value % contribution

Model 1968.96 16 123.06 3.40 0.0423
Working Gap 1284.24 4 321.06 8.87 0.0049 56.86
Electrolyte Flow Rate 88.24 4 22.06 0.6092 0.6676 3.91
Electrolyte Current 453.84 4 113.46 3.13 0.0793 20.09
Workpiece Rotational Speed 142.64 4 35.66 0.9848 0.4676 6.32
Residual 289.68 8 36.21 12.82
Cor Total 2258.64 24

4.4. Effect of process parameters on MR decrease the cutting force which is responsible for MR. As the elec-
trolytic flow rate is increases from the 5 lit/hr., MR is decrease. This
Fig. 5 shows the effect of various process parameters on the MR may be due to electrolyte particles pass away from electrode gap
of SS 304 workpiece. As the working gap increases, MR is without completing chemical process due to very high velocity.
decreases. This is because as the working gap is increases; mag- But after 20 lit/hr. flow rate, MR is starts to increases because at
netic flux density in the working gap is decreases and hence very high velocity, impact of jet of electrolyte is become significant
decrease in magnetic force acting on the abrasive particles and this and increase in MR.

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A.R. Chaudhari and K.B. Judal Materials Today: Proceedings 49 (2022) 390–396

Table 7
Response of Signal to Noise Ratios for SR (Smaller is better).

Level WorkingGap in mm ElectrolyteFlow Ratein Lit./Hr. ElectrolyteCurrent inAmp WorkpieceRotationalSpeed in RPM

2 10.854 9.590 9.786 9.774
1 9.754 9.945 10.200 10.498
0 9.457 9.404 9.507 9.598
1 9.372 9.735 9.349 9.399
2 9.157 9.920 9.752 9.324

Table 8
Response of Signal to Noise Ratios for MR (larger is better).

Level WorkingGap in mm ElectrolyteFlow Ratein Lit./Hr. ElectrolyteCurrent inAmp WorkpieceRotationalSpeed in RPM

2 31.04 28.28 26.06 23.83
1 29.19 27.57 24.77 27.57
0 24.95 26.39 25.30 27.67
1 24.25 25.50 28.09 27.77
2 24.56 26.24 29.78 27.15

Fig. 4. Effect of process parameters on SR.

While observing effect of electrolytic current, it is found that as rotational speed, electrolytic flow rate and electrolyte current on
electrolytic current increases, there is increase in MR due to more SR and MR has been discussed. The following inferences are
current accelerate the electrolysis rate and increase in passivation derived:
and more removal of material. It is also observed that as workpiece
rotational speed increases initially from 500 RPM; MR is increases 1. Newly developed ECMAF set up eliminates problem of washing
rapidly because as RPM increases, surface finishing length per unit of abrasive particles from the working gap.
time is increases. After the increase in rotational speed from 1000 2. ECMAF is the feasible process to finish SS 304 workpiece and
RPM, MR is increases very slowly and after 2000 RPM, it is started maximum improvement in the SR can be obtained by
to decreases. This is due to very much increase in centrifugal force 0.239 mm at 12.34 signal to noise ratio and maximum MR can
on the abrasive particles, which reduce the abrasion force and be obtained as 47.4 mg at 36.48 signal to noise ratio.
decrease in MR. 3. The working gap is found to be the most significant process
parameters followed by workpiece rotational speed and elec-
trolyte current for SR as their p values are less than 0.05.
5. Conclusion 4. For MR, the working gap is found to be the most significant pro-
cess parameter as their p values is less than 0.05.
In this paper, experimentation on indigenously developed
ECMAF set up has been carried out and evaluated the finishing per-
formance of SS 304workpice. The effect of working gap, workpiece
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A.R. Chaudhari and K.B. Judal Materials Today: Proceedings 49 (2022) 390–396

Fig. 5. Effect of process parameters on MR

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4V using shear thickening fluids additives, Precision Engineering 64 (2020)
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