Nanofinishing Process for 3D Freeform Surfaces Using Ball End MR Finishing Tool

Abstract

A new precision finishing process for nanofinishing of 3D freeform surfaces using ball end MR finishing tool is developed. The newly developed finishing process is useful to finish ferro magnetic as well as non-magnetic materials of 3D freeform surfaces using specially prepared magnetorheological polishing (MRP) fluid. The smart behaviour of MR-polishing fluid is utilized to precisely control the finishing forces, hence final surface finish. The existing MR finishing devices and methods are likely to incapable of finishing of 3D freeform surfaces due to restriction on relative movement of finishing medium and work piece. In this newly developed finishing device, the ball end MR finishing tool is used for finishing of different kinds of 3D surfaces where there are no such limitations of relative movement of finishing medium and workpice.It can finish the work surfaces as same as the machining of 3D freeform surfaces by CNC ball end milling cutter and open a new era of its applications in future. The developed process may have its potential applications in aerospace, automotive and molds manufacturing industries. A computer controlled experimental setup is designed to study the process characteristics and performance. Maxwell simulations were done on ferro magnetic as well as non ferro magnetic materials of 3D surfaces to observe the ball end shape of magnetic field intensity at the tip of the MR finishing tool.