SELECTION OF OPTIMUM DESIGN OF MR FINISHING TOOL AND ITS ANALYSIS FOR FINISHING OF EN-31 WORKPIECE SURFACE

Abstract

Magneto-rheological finishing (MRF) is a novel and promising technique used for precision machining and polishing of various workpiece materials. Present work is aimed to design MR finishing tool in ANSYS Maxwell 3D simulation software for finishing variety of workpiece materials. Design of experiment has been used with two parameters such as bush height and number of turns to develop the experimental plan using design expert software. Modelled MR finishing tool has been tested with different experimental run to observe the shape and intensity of magnetic field at MR finishing tool tip. Statistical analysis has been done to see the effect of bush height and number of turns on magnetic field intensity at MR finishing tool tip. Linear model has been selected in the analysis and analysis of variance (ANOVA) has been done with model p values less than 0.0001 along with F value 566.41 which indicates that the model selected is significant and lack of fit with p value 0.1265 indicates insignificant. Regression equation has been obtained in coded form as well as actual form to see the effect of bush height and number of turns on response intensity of magnetic field at MR finishing tool tip. It has been observed that the predicted intensity of magnetic field at tool tip is found 1.99885 T for bush height 6.63 mm and number of turns 2133. After obtaining predicted intensity of magnetic field, numerical optimization has been carried out and found that maximum intensity of magnetic field is obtained 1.999 T for bush height 6.628 mm and number of turns 2132 which is very close to the predicted value of magnetic field intensity.