Magnetorheological fluid-based finishing is one of the recognized techniques for precisely finishing of a variety of components. Material removal depends largely on velocity and compression of the magnetorheological (MR) fluid ribbon when it interacts with the workpiece. This article studies the throwing of magnetic and abrasive particles during carrier wheel rotation. Theoretically computed centrifugal and magnetic forces are balanced against each other to determine the speed at which these particles are ejected from the MR fluid. The results of experiments at various carrier wheel speeds show the reduction of MR fluid ribbon thickness at higher wheel speed due to throwing of MR fluid. As a result of particle separation from the MR fluid at high rotational speed. As the carrier wheel speed increases, surface roughness decreases initially and then increases. There is good agreement between theoretical and actual results for the spindle speed at which magnetic particles depart the MR fluid ribbon.
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