Optimum selection of machining parameters in ball end magnetorheological finishing process

Abstract

Ball end magnetorheological finishing (BEMRF) tool has been used to finish mild steel work-piece surface using sintered magnetic abrasives based magnetorheological polishing (MRP) fluid. A comparative study has been done on mild steel surface with synthesised and unbounded magnetic abrasives based MRP fluid. Then percent reduction in surface roughness (%∆Ra) was calculated and compared. The response %∆Ra was found superior while finishing with synthesised MRP fluid. A detailed study with five levels and three factors central composite design of experiments (DOEs) was done to develop experimental plan. Response surface methodology (RSM) was adopted to predict the profile and %∆Ra. An effective second order response surface model was developed with significant factors and their interactions. Physical interpretation of effect of machining parameters on %∆Ra was analysed and obtained optimum values. Then experiment was conducted with optimum machining parameters and %∆Ra was calculated and compared with maximum %∆Ra obtained by regression model.