Spatial-Spectrum-Based Measurement of the Surface Roughness of Ferromagnetic Components Using Magnetic Flux Leakage Method

Smart sensing of the surface roughness values is of great importance for intelligent manufacturing when online surface roughness measurements are essential in optimizing the machining processes. In this article, the magnetic flux leakage (MFL) method is applied to assess the roughness of triangle array surfaces, which may result from milling, turning, and planing. The leakage magnetic field (LMF) distribution is obtained by the magnetic dipole theory. The Fourier transform (FT) method is adopted to obtain the spatial spectrum functions of the LMF. Surface topography parameters are characterized from the first pulsed position and the correlation coefficient in the spatial spectrum domain. A magnetic recording head is designed for experimental verification. The results show that the relative errors of the surface roughness values are less than 13%. In addition, a portable probe used for roughness measurements is developed for a machining tool with an electromagnetic fixture. Fourier transform (FT), electromagnetic fixture, magnetic flux leakage (MFL), spatial spectrum, surface roughness.

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