Computational fluid dynamics simulation and experimental investigations into the magnetic-field-assisted nano-finishing process

Abstract

This article deals with a new approach to understand the magnetic-field-assisted nano-finishing process in which computational fluid dynamics is used to simulate the forces. A finite element method is used to evaluate the magnetic field intensity, mathematical modelling is applied to model the nano-finishing operation, and the experiments are conducted to compare the experimental results with the simulated results. A flexible polishing tool comprising a magnetorheological polishing medium is used for this process. The relative motion between the polishing medium and the workpiece surface provides the required finishing action. In the present work, a two-dimensional computational fluid dynamics simulation of a magnetorheological polishing medium inside the workpiece fixture is performed to evaluate the axial and radial stresses developed owing to the flow of magnetically stiffened magnetorheological polishing medium. A finite element analysis is performed in order to find out the direction and the magnitude of the magnetic field. A microstructure of the mixture of magnetic and abrasive particles in the magnetorheological polishing medium is proposed in order to calculate forces acting on an active abrasive particle. Modelling of the surface finish is performed after analysing the surface roughness profile data. Further finishing experiments are conducted in order to compare the simulated surface roughness value with the experimental results and they are found to agree well.