On August 13, 2026

Experimental Investigation and Multi-Objective Optimisation of Dual-Pole Ultrasonic-Assisted Magnetic Abrasive Finishing (DP-UMAF) for Surface Enhancement of Ti-6Al-4VAerospace Alloy

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Although the Ti-6Al-4V titanium alloy possesses outstanding specific strength, compatibility with
biological tissue and corrosion resistance, it is still considered a challenging material to machine, making
it difficult to create ultra-smooth surfaces (Ra < 0.1 μm). The conventional finishing methods exhibit low
efficiency, high tool wear and have limited ability to achieve nanometric surface quality. The recent
Single-Pole Magnetic Abrasive Finishing (SP-MAF) research in literature by Singh et al. indicated that
the minimum surface roughness obtained was as low as 0.140 μm with comparatively softer zinc
substrates, thus highlighting the need for further study to achieve similar surface roughness with harder
engineering alloys such as Ti-6Al-4V. To overcome this limitation, a novel DP-UMAF process is
proposed in the present study, which combines the improved magnetic field distribution with high-
frequency ultrasonic excitation. A Box–Behnken Response Surface Methodology was used to
systematically investigate the process performance, with a total of 32 experimental runs and eight
controllable factors: the rotational speed of FMAB (250–1500 RPM), work gap (1–3 mm), feed rate (1–5
mm/s), ultrasonic frequency (20–40 kHz), ultrasonic amplitude (5–20 μm), magnetic flux density (0.3–0.8
T), abrasive mesh size (400–1200), and finishing time (5–30 min). Experimental findings showed that the
surface roughness was reduced by 76.3% from 0.312 μm to 0.074 μm with the material removal rate of
6.72 mg/min (183.5% higher than the conventional MAF). The parameters that had the greatest influence
were identified by the analysis of variance: FMAB speed (F = 7825.4) and ultrasonic amplitude (F =
3763.2) and the model that was developed demonstrated good predictive capacity (Adjusted R² =

99.81%). The high performance of DP-UMAF is due to its dual-pole construction, which creates an
almost 1.85 times higher magnetic flux density and the ultrasonic vibration that reduces abrasive clogging
and tool–workpiece adhesion. The process suggested in the present work shows great potential for
precision finishing of the titanium alloys, which can provide an effective route for improvement of the
surface integrity and consequently increase the manufacturing productivity.

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