Nano finishing of miniature-diameter copper tube using magnetorheological finishing

Abstract

Nano finishing of small surfaces has become a challenging task in various industries such as automotive, machine tool, aerospace, and others. These miniature surfaces require a specially designed tool for their precise surface finishing. In the existing work, the magnetorheological (MR) finishing process replaces grinding, lapping, or honing processes to provide fine surface finishing through the use of gel-like smart fluid. The fluid contains a suspension of abrasive and iron particles along with grease and paraffin oil. With the use of Maxwell Ansoft software, a magnetic simulation was performed to verify the dispersion of the magnetic field. The safety and effectiveness of the tool design were well demonstrated by this simulation. Thereafter, the optimization study revealed with workpiece rotations of 300 rpm, tool linear speed of 70 cm/min, and completion time of 50 minutes, the maximum percentage change in surface roughness (Ra) value was found as 70%.