Design and Development of Improved Ball End Magnetorheological Finishing Tool with Efficacious Cooling System

Abstract

Ball end magnetorheological finishing is a magnetic field-assisted nano-finishing process in which the electromagnet is used to generate the required magnetic field. The electromagnet is energized by DC current which also generates heat in the electromagnet. Nano-finishing is a time-taking process which requires the machine to run for a long time such as hours or days. Sometimes the material which is to be finished requires higher magnetic field for finishing. Due to these two reasons, it requires continuous cooling of the electromagnet so that the finishing operation can be prolonged without stopping the finishing operation. To see the above requirements, a new cooling system has been developed in which the electromagnet is cooled continuously by the electrically insulating oil circulated at low temperature. In this new cooling system, the electromagnet is cooled from the inside too for effective cooling of the inner layers of the copper wire. Results on this newly designed tool show that it continuously works without getting heated.