Abstract
An improved magnetorheological finishing process has been developed with three permanent magnets for nano finishing the external surface of cylindrical workpieces. The cylindrical permanent magnets used in the developed tool are placed at an angle of 90° from each other. The three cylindrical permanent magnets are positioned in such a way that all three maintain an equal working gap with the surface of cylindrical workpiece. Finite Element (FE) analysis of the entire setup has also been performed in the Maxwell Ansoft V13 software to observe the dispersal of magnetic field density in the working gap. In the current study, the preliminary experimentations have been carried out to evaluate the finishing capability of the present developed tool. Experiments have been conducted over the external cylindrical workpiece made of copper which can be used as an electron discharge machining (EDM) electrode. After the experimentations of 45 min over the entire cylindrical workpiece made of copper, the average surface roughness Ra gets reduced from 224 to 67 nm with negligible surface defects which confirm the finishing performance of the developed finishing tool.
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