Focusing on the gap between a fixed-abrasive tool and workpiece, the machining characteristics of the fixed-abrasive machining of a Ti-6Al-4V extra low interstitial (ELI) alloy with magnetic brush were evaluated, which removed material through the combined actions of the fixed abrasive and magnetic brush. Machining experiments demonstrated that the material removal was mainly performed by the fixed abrasive, while the magnetic brush removed the swell out residuals associated with this removal. As a result, it was found that fixed-abrasive machining with a magnetic brush was capable of reducing the finished-surface roughness to 50% or less compared to fixed-abrasive machining alone, although the removal depth was also decreased. This proved that fixed-abrasive machining with a magnetic brush is useful for machining materials whose removal involves plastic deformations.

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