Experimental studies on the ultra-precision finishing of cylindrical surfaces using magnetorheological finishing process

Abstract

In modern manufacturing and assemblies, high-dimensional accuracy and fine surface finishing play an important role. One of the most promising methods of fabricating such high-precision parts is magnetorheological finishing process. In cylindrical components grinding, the external surface is ground and by obtaining a high-precision finished surface these components will perform better in mechanical systems. This process is not readily applicable to magnetizable materials, if a high-magnetic field is used. This is due to the attraction of workpiece by magnetic force and preventing it to rotate. In this study, the main mechanism is responsible for the decrease of Ra on external surface of cylindrical workpieces made of non-magnetizable materials, and a new method based on MRF process is examined. The examined specimens in this study are made of aluminum (Al), it is known as a kind of non-magnetizable, soft, and lightweight materials. The apparatus that used for this experiment includes two main motions. The first one is using a rectilinear alternating motion to improve processing conditions, and the second one is specimen’s rotational motion. The experiments of this study show the applicability of this method for finishing cylindrical surfaces made of Al.