Research on the tool influence function characteristics of magnetorheological precession finishing (MRPF)

Abstract

Magnetorheological finishing (MRF) technology is characterized by its high convergence rate and minimal subsurface damage as advantages. However, the non-Gaussian type tool influence function (TIF) it generates may cause mid-frequency errors and oriented surface texture issues. Magnetorheological precession finishing (MRPF) technology capable of generating Gaussian-like removal functions, lacks a clearly defined removal function model. This study acquired polishing spots in tilted polishing, discrete precession, and continuous precession modes via fixed-point polishing experiments. Using Multiphysics simulation software, stress and velocity distribution in the contact area were simulated. A TIF model, incorporating the synergistic effects of pressure and shear force and multiple influence coefficients, was proposed based on velocity characteristics across the three modes. To accurately predict the TIF, surface topographies with varying coefficients were constructed using this model, analyzing the coefficients’ impact on the TIF profile. Optimal coefficients were identified using a least fit error algorithm. Further analysis of the TIF's internal textures revealed that the precession mode of MRPF yields superior surface quality, thereby elucidating the material removal mechanism of MRPF and laying a theoretical groundwork for advancing processing technologies.