Abstract
A new magnetorheological honing process is developed to fulfill the requirement for finishing the internal surface of ferromagnetic workpieces. In this process, the electromagnetic tool with retained MR polishing fluid moved inside the ferromagnetic cylindrical-type workpiece as similar to traditional honing tool for precise surface finishing. Response surface methodology is carried out to plan and evaluate the effect of different process parameters for determining the percentage change in surface roughness (Ra) values. The experimental analysis revealed that the higher percentage change in Ra values is determined by magnetizing currents followed by tool linear speeds, mesh sizes of CIPs, tool rotational speeds, and mesh sizes of SiC abrasive particles. The surface roughness (Ra) value is found as 96 nm from initial 401 nm after 90 min of finishing with the optimum process parameters. The application of present magnetorheological honing process is found in internal surface finishing of injection barrel, bearings, etc.
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