Design and fabrication of a novel magnetorheological finishing process for small concave surfaces using small ball-end permanent-magnet polishing head. Issue 5 (March 2016)

• Record Type: Journal Article
• Authors: Chen, Mingjun; Liu, Henan; Su, Yinrui; Yu, Bo; Fang, Zhen
• Is Part Of: International journal of advanced manufacturing technology. Volume 83:Issue 5/8(2016)
• Page Start: 823
• Page End: 834
• Publication Date: 2016-03
• Subjects: Magnetorheological finishing -- Magnetostatic simulation -- Surface roughness -- Small curvature radius; Manufacturing processes -- Periodicals; Production engineering -- Periodicals; 670.427
• DOI: 10.1007/s00170-015-7573-5
• Languages: English
• ISSNs: 0268-3768

Abstract

Abstract In order to overcome the defects of conventional magnetorheological finishing (MRF) processes that are unable to finish small curvature radius concave surfaces of diameter within 10 mm, a novel precision MRF process using small ball-end permanent-magnet polishing head with a diameter of 4 mm is proposed in this paper. And experimental setup of a four-axis linkage MRF machine tool is fabricated. Magnetostatic simulation of the distribution of magnetic flux density indicates that the magnetic field uniformity of produced polishing head is 93.3 %. Magnetizing force analysis is done to analyze the formation of magnetorheological fluid in finishing region. In addition, the suitable range of C-axis angular position for finishing is generated to be 60°~70°. Finishing experiments on both nonmetallic and metallic specimens with different surface shapes have been conducted. The ability of the developed method of finishing process to improve surface characteristics of a workpiece is demonstrated to reach the surface roughness of finished surfaces below Ra 6 nm. It confirms that the present MRF process is capable of improving surface quality and performing the nanofinishing on small curvature radius concave surfaces.