Analysis of finishing forces and surface finish during magnetorheological abrasive flow finishing of asymmetric workpieces

Abstract

Magnetorheological abrasive flow finishing (MRAFF) is an advanced hybrid process for producing ultrafine finished surfaces. Such surfaces reduce frictional forces and thereby minimize wear and tear to increase functional lifetime of the components. In the present research work, a model has been developed for simulating the results of MRAFF process. First, magnetic field is simulated and then a detailed study on the rheology of the magnetorheological polishing (MRP) fluid is conducted to develop a viscosity model for the flow of non-Newtonian shear thinning fluid. To calculate the forces acting in the process of material removal, the flow of MRP fluid around an asymmetric workpiece (knee joint) in a spatially varying magnetic field is simulated. Finishing forces exerted by the abrasive particles on the workpiece surface are analysed to develop a model for predicting surface roughness. A methodology has been proposed to evolve a variable correction factor to determine active abrasive particles at different locations on the workpiece surface for accurate simulation of surface finish operation. It is found that the magnetic field greatly influences the process performance by governing the viscosity of the MRP fluid and the distribution of the abrasive particles in the medium. During finishing of an asymmetric workpiece, the surface finish obtained at different locations on the workpiece surface is different. The developed model is capable to predict final surface finish within the acceptable accuracy when compared with the experimental results.