Effect of optimum process parameters on material removal in rotational-magnetorheological miniature gear profile polishing (R-MRMGPP) process

The traditional finishing method causes form inaccuracy in miniature gear profiles due to the transverse grinding line, fine microcrack, claw-mark, burr, pit and thermal distortions. Because of the small space between their teeth, tiny gear can only be polished in a very few ways. This article reports on the new flow restrictor used in rotational-magnetorheological miniature gear profile polishing (R-MRMGPP) process for precise polishing of miniature gear profiles. The response surface method (RSM) is utilized to investigate the effect of key factors on process performance. Further, simulation of finishing forces is conducted using COMSOL® Multiphysics software, which is based on finite element analysis (FEA). The study of finishing forces assists in accurately understanding the processing mechanism. A model is also simulated to determine the depth of indentation produced by an abrasive on SS316L miniature gear tooth profile due to normal finishing forces. Experimental results identified that combining a higher number of finishing cycles, a lower volumetric proportion of iron/abrasive particles, and a higher extrusion pressure is more favourable to obtain high material removal rate (MRR).