Effect of Polishing Fluid Composition on Forces in Ball End Magnetorheological Finishing Process

Zafar Alam, Dilshad Ahmad Khan, Faiz Iqbal, Sunil Jha

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract / Description of output

Ball end magnetorheological finishing (BEMRF) is a nanofinishing process used for fine finishing of flat as well as complex 3D surfaces of a variety of materials. In magnetically energized state, magnetorheological polishing (MRP) fluid containing carbonyl ironparticles (CIPs) and polishing grade abrasives is used to remove materials from the workpiece surface. The composition of the MRP fluid greatly influences the forces during the finishing process. Using a dynamometer both normal and shear forces applied by the MRP are recorded on-line. A central composite design of experiments is used to plan the experiments and ANOVA to correlate these forces and process parameters. The process parameters selected here are vol.% of CIPs and vol.% of abrasives which are varied from 5% to 25% and 5% to 20% respectively to measure the forces during experimentation. Both normal and shear forces increase with increase in the CIPs content in the fluid. This is because higher concentration of CIPs increases the magnetic permeability of the MRPfluid making it stiffer when exposed to magnetic field. In case of abrasive concentration it is observed that the forces initially increase with increase in abrasive content but begins to decline after a certain point. The hypothesis behind this is that initially the increased abrasives fill the void between the CIPs chains and strengthens the chain structure of the fluid. However beyond a certain point increased number of abrasives hinders the chain formation leading to the increase in number of broken chains. This decreases the forces during finishing
Original languageEnglish
Title of host publicationEffect of Polishing Fluid Composition on Forces in Ball End Magnetorheological Finishing Process
Publication statusPublished - 9 Dec 2017

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