Ball-end magnetorheological finishing (BEMRF) is a high-efficiency nano-finishing technology based on smart magnetorheological fluid to polish complex materials precisely. The surface roughness can be linked with the experimental data to understand the finishing mechanism based on advancements in manufacturing automation and the prediction of material removal. This study proposes a mathematical model to predict surface roughness, helping to understand the effects of various process parameters on surface quality during the BEMRF process. This study adds value to practitioners by providing a mathematical model to predict the optimum parameters for attaining the desired surface finish in BEMRF polishing.
KumarM, KumarA, AlokA, . Magnetorheological method applied to optics polishing: A review. IOP Conf Ser Mater Sci Eng2020; 804: 012012.
2.
HaoL, LiuZ, LiS, . Analysis on affecting factors of magnetorheological finishing. J Phys Conf Ser2021; 1750: 012067.
3.
MutalibNA, IsmailI, SoffieSM, . Magnetorheological finishing on metal surface: A review. IOP Conf Ser Mater Sci Eng2019; 469: 012092.
4.
KordonskiW and ShoreyA.Magnetorheological (MR) jet finishing technology. J Intell Mater Syst Struct2007; 18:1127–1130.
5.
JhaS and JainVK.Nanofinishing of silicon nitride workpieces using magnetorheological abrasive flow finishing. Int J Nanomanuf2006; 1: 17–25.
6.
PanJ, ZhengK, YanQ, . Optimization study on magnetorheological fluid components and process parameters of cluster magnetorheological finishing with dynamic magnetic field for sapphire substrates. Smart Mater Struct2020; 29: 114009.
7.
JhaS and JainVK.Design and development of the magnetorheological abrasive flow finishing (MRAFF) process. Int J Mach Tools Manuf2004; 44: 1019–1029.
8.
SambhariaJ and MaliHS.Recent developments in abrasive flow finishing process: A review of current research and future prospects. Proc Inst Mech Eng Part B J Eng Manuf2019; 233: 388–399.
9.
MildeR, BílekO, SedlacíkM, . Construction of magnetorheological device for finishing of non-metallic materials. IOP Conf Ser Mater Sci Eng2020; 726: 012009.
10.
SinghAK, JhaS and PandeyPM.Nanofinishing process for 3D freeform surfaces using ball End MR finishing tool. In Proceedings of the 36th International MATADOR Conference, 2010, 67–70. Springer London.
11.
AnantKS, JhaS and PulakMP.A novel ball end magnetorheological finishing process. In Proceedings of then ASME International Mechanical Engineering Congress and Exposition, (IMECE), Montreal, QC, 2014.
12.
SaraswathammaK, JhaS and RaoPV.Experimental investigation into ball end magnetorheological finishing of silicon. Precis Eng2015; 42: 218–223.
13.
SaraswathammaK, JhaS and Venkateswara RaoP.Rheological behaviour of magnetorheological polishing fluid for Si polishing. Mater Today Proc2017; 4: 1478–1491.
14.
SaraswathammaK, JhaS and RaoPV.Rheological characterization of MR polishing fluid used for silicon polishing in BEMRF process. Mater Manuf Process2015; 30: 661–668.
15.
Kumar SinghA, JhaS and PandeyPM.Design and development of nanofinishing process for 3D surfaces using ball end MR finishing tool. Int J Mach Tools Manuf2011; 51: 142–151.
16.
SinghAK, JhaS and PandeyPM.Parametric analysis of an improved ball end magnetorheological finishing process. Proc Inst Mech Eng Part B J Eng Manuf2012; 226: 1500–1563.
17.
SinghAK, JhaS and PandeyPM.Mechanism of material removal in ball end magnetorheological finishing process. Wear2013; 302: 1180–1191.
18.
Kumar SinghA, JhaS and PandeyPM.Nanofinishing of a typical 3D ferromagnetic workpiece using ball end magnetorheological finishing process. Int J Mach Tools Manuf2012; 63: 21–31.
19.
LeeJW, HaSJ, ChoYK, . Investigation of the polishing characteristics of metal materials and development of micro MR fluid jet polishing system for the ultra precision polishing of micro mold pattern. J Mech Sci Technol2015; 29: 2205–2211.
20.
PaulJ, LimWM, O’CassA, . Scientific procedures and rationales for systematic literature reviews (SPAR-4-SLR). Int J Consum Stud2021; 45: 1–16.
21.
van EckNJ, and Waltman L. Software survey: VOSviewer, a computer program for bibliometric mapping. Scientometrics2010; 84: 523–538.
22.
DuH, SongC and LiS.Study on surface roughness of modified silicon carbide mirrors polished by magnetorheological finishing. IOP Conf Ser Mater Sci Eng2018; 301: 012164.
23.
KhanDA, JhaS.Selection of optimum polishing fluid composition for ball end magnetorheological finishing (BEMRF) of copper. Int J Adv Manuf Technol2019; 100: 1093–1103.
24.
AlamZ, IqbalF and JhaS.Automated control of three axis CNC ball end magneto-rheological finishing machine using PLC. Int J Autom Control2015; 9: 201–210.
25.
QianC, FanZ, TianY, . A review on magnetic abrasive finishing. Int J Adv Manuf Technol2021; 112: 619–634.
26.
NiranjanM, JhaS and KotnalaRK.Ball end magnetorheological finishing using bidisperse magnetorheological polishing fluid. Mater Manuf Process2014; 29: 487–492.
27.
NiranjanMS, and JhaS.Statistical analysis of magnetorheological ball end finishing parameters using response surface methodology. Int J Manuf Technol Manag2016; 30: 240–252.
28.
IqbalF, AlamZ and JhaS.Modelling of transient behaviour of roughness reduction in ball end magnetorheological finishing process. Int J Abras Technol2020; 10: 170–192.
29.
BaghelPK, and KumarR.Estimation of magnetorheological fluid constituent’s concentration for efficient finishing process. Mater Manuf Process2021; 36: 626–635.
30.
KumarJ, NegiVS, ChattopadhyayKD, . Thermal effects in single point diamond turning: Analysis, modeling and experimental study. Meas J Int Meas Confed2017; 102: 96–105.
31.
ZhuX, MengY and TianY.Nonlinear pressure-dependent conductivity of magnetorheological elastomers. Smart Mater Struct2010; 19: 117001.
32.
ChenY, HuangW, ZhangY, . Novel high efficiency deterministic polishing method using magnetorheological elastomer. Smart Mater Struct2020; 29:114008.
33.
KumarM, KumarA, AlokA, . Magnetorheological method applied to optics polishing: A review. IOP Conf Ser Mater Sci Eng. 2020; 804: 012012.
34.
DubeyNK, and SidparaA.Numerical and experimental study of influence function in magnetorheological finishing of oxygen-free high conductivity (OFHC) copper. Smart Mater Struct2021; 30: 015034.
35.
LiR, LiX, YangPA, . The field-dependent surface roughness of magnetorheological elastomer: Numerical simulation and experimental verification. Smart Mater Struct2019; 28: 085018.
36.
LuoB, YanQ, HuangZ, . Machining method for controlling the behaviours of Bingham fluids in cluster magnetorheological polishing pads. Smart Mater Struct2021; 30: 025002.
37.
LeeJW, HongKP, ChoMW, . Polishing characteristics of optical glass using PMMA-coated carbonyl-iron-based magnetorheological fluid. Smart Mater Struct2015; 24: 065002.
38.
JonkkariI, KostamoE, KostamoJ, . Effect of the plate surface characteristics and gap height on yield stresses of a magnetorheological fluid. Smart Mater Struct2012; 21: 075030.
