Improved magnetorheological finishing process with rectangular core tip for external cylindrical surfaces

Abstract

ABSTRACTFinishing of the external surface of cylindrical components at nano-level using magnetorheological process has witnessed for rising demand in the manufacturing industries to improve its functional applications. In this paper, the best required shape of the tool core tip surface in the magnetorheological finishing process is attempted to design for improving the efficiency of the process on external cylindrical surfaces. The different shapes of the tool core tip surface are designed, and their performance was analysed with the help of magnetostatic finite element analysis. The design of a rectangular shaped tool core tip surface is found more effective for uniform and higher flux density. The experiments are conducted on the cylindrical external surface using the recently developed rectangular and existing circular shaped tool core tip surfaces. After the magnetorheological finishing with rectangular and circular shaped tool core tip surfaces, the final surface roughness values get reduced to 18 nm and 45 nm from the initial value of 310 nm. Surface waviness, characteristics and mirror images are also found better while magnetorheological finishing performed using the rectangular core tip surface. Hence, the rectangular shaped design of the tool core tip surface is found to be more useful in improving the effectiveness of the present process.