DESIGN AND ANALYSIS OF MR FINISHING TOOL FOR NANO LEVEL FINISHING ON NON-FERROMAGNETIC WORKPIECE SURFACE

Abstract

The magnetorheological (MR) finishing process is an innovative technique used for precision polishing of various materials. The present work is aimed to design and analyze the MRF process using ANSYS Maxwell simulation software and STAT-EASE360 software. The MRF process involves the controlled application of magnetorheological fluid (MRF) to a workpiece, which responds to change its properties in an applied magnetic field and produces a polishing effect. The design phase encompasses the modeling of MR Finishing tool in ANSYS Maxwell software and development of model in STAT-EASE360 software. The simulation are run for different combination of bush height and number of turns obtained by STAT-EASE360 software. The maximum magnetic flux density of 1.941 Tesla was observed at bush height of 5 mm and number of turns 2000. Then a crucial analysis has been performed for magnetic flux density using three different MR fluids at bush height 5mm and number of turns 2000. The simulation results provide valuable insights into the behavior of the MR fluid in the finishing process. The maximum flux density has been found to be 1.740 Tesla for MRF-122EG for bush height 5mm and number of turns 2000. Furthermore, the analysis phase involves employing analysis of variance (ANOVA) techniques to evaluate the influence of various process parameters on the output response. ANOVA allows for a statistical assessment of the significance of bush height and number of turns and its interaction with magnetic flux density, thereby aiding in process optimization and improvement. The predicted value of magnetic flux density was found to be 2.00994 Tesla, whereas the optimized value of magnetic flux density was found to be 2.010 Tesla at bush height 6.63 mm and number of turns 2133. The findings from the ANSYS Maxwell simulation and ANOVA analysis provide valuable information for enhancing the efficiency and effectiveness of the MRF process. The optimized design parameters can lead to improved surface quality, reduced processing time, and increased material removal rates, making the MRF process an attractive option for precision polishing in various industries.