Experimental Study of Several Tools for Surface Roughness obtained using Magnetorheological Abrasive Flow Finishing Process

Abstract

The main objective of this work is to prepare MR fluid and investigating the various shape of flask and to determine the effect of various shape of tools on the surface of MS specimen and also verifying the stability of prepared MR fluid by using magneto rheological abrasive flow finishing process. So, in order to establish the process, the experimental set up is developed on which various trials have been conducted by considering the various shape of the tools and shape of flask. The magneto- rheological fluid consists of CI particles with mesh size 300, nonmagnetized Al2O3 and SiC abrasive powder with mean sizes of 67.496 and 326.04 μm respectively. Combinations of the two abrasives, Al203 and SiC, with CI particles were used with servo 4T oil as a carrier fluid. It was observed that the removal rate increases with increased percentage of polishing abrasives. The relative increase depends upon the amount and type of abrasives used. Hence the improvement in surface roughness is considered as an outcome of the process. MR fluid with CI particles and Al₂O₃/SiC abrasives in 4T oil improves surface finish. Turned finishing tool gives best results with magnetic field strength of 0.217 Tesla from 4370 turns. Tools made from multiple parts should not be deployed as its results in poor surface finish due to cumulative inaccuracies in the assembly of the parts. MRAFF can be used to finish ferrous materials using a stagnant fluid bath.