Performance Evaluation of Improved Ball End Magnetorheological Finishing Process
A novel nanofinishing process using improved ball
end magnetorheological (MR) finishing tool was developed for finishing of flat as well as 3D surfaces of ferromagnetic and non ferromagnetic workpieces. In this process a magnetically controlled
ball end of smart MR polishing fluid is generated at the tip surface of
the tool which is used as a finishing medium and it is guided to
follow the surface to be finished through computer controlled 3-axes
motion controller. The experiments were performed on ferromagnetic
workpiece surface in the developed MR finishing setup to study the effect of finishing time on final surface roughness. The performance
of present finishing process on final finished surface roughness was studied. The surface morphology was observed under scanning
electron microscopy and atomic force microscope. The final surface finish was obtained as low as 19.7 nm from the initial surface
roughness of 142.9 nm. The outcome of newly developed finishing process can be found useful in its applications in aerospace,
automotive, dies and molds manufacturing industries, semiconductor and optics machining etc.
[1] V. K. Jain, S. C. Jayswal, P. M. Dixit, "Modeling and Simulation of Surface Roughness in Magnetic Abrasive Finishing Using Non-Uniform Surface Profiles," Materials and Manufacturing Processes, vol. 22/2,
pp. 256 - 270, 2007.
[2] Z. W. Zhong, "Recent Advances in Polishing of Advanced Materials,"
Materials and Manufacturing Processes, vol. 23/5, pp. 449 - 456,2008.
[3] T. Hoshino, Y. Kurata, Y. Terasaki, K. Susa, "Mechanism of polishing
of SiO2 films by CeO2 particles," Journal of Non-Crystalline Solids,
vol. 283, pp. 129-136, 2001.
[4] S.D. Jacobs, D. Golini, Y. Hsu, B.E. Puchebner, D. Strafford, Wm.I. Kordonski, I.V. Prokhorov, E. Fess, D. Pietrowski, V.W. Kordonski,
"Magnetorheological finishing: a deterministic process for optics manufacturing," International Conference on Optical Fabrication and
Testing, 1995, Proc. SPIE 2576, T. Kasai, ed., pp. 372-382.
[5] D. Golini, S.D. Jacobs, W. Kordonski, P. Dumas, "Precision optics
fabrication using magnetorheological finishing," in Advanced Materials
for Optics and Precision Structures, vol. CR67 of SPIE, 1997, pp. 251-274.
[6] W.I. Kordonski, S.D. Jacobs, "Magnetorheological finishing,"
International Journal of Modern Physics B, vol. 10, pp. 2857-
2865,1996.
[7] A.B.Shorey , S.D.Jacobs,W.I. Kordonski ,R.F. Gans , "Experiments and
observations regarding mechanisms of glass removal in magnetorheological finishing," Applied Optics , vol. 40/1, pp. 20-33,2001.
[8] W.Kordonski, D.Golini, P. Dumas, S. Jacobs, "Magnetorheological
suspension-based finishing technology", Proc. SPIE 3326, pp. 527-535, 1998.
[9] Donald Golini, William I Kordonski, Paul Dumas, Steve Hogan,
"Magnetorheological finishing (MRF) in commercial precision optics
manufacturing," Proc. SPIE 3782 conference on optical manufacturing
and testing, pp. 80-90, 1999.
[10] A. Kumar Singh, S. Jha, P.M. Pandey, "Design and development of
nanofinishing process for 3D surfaces using ball end MR finishing
tool," International Journal of Machine Tools & Manufacture, vol. 51,
pp. 142-151, 2011.
[11] S. Jha, V.K. Jain, "Design and development of the magnetorheological
abrasive flow finishing (MRAFF) process," International Journal of
Machine Tools & Manufacture, vol. 44, pp. 1019-1029, 2004.
[1] V. K. Jain, S. C. Jayswal, P. M. Dixit, "Modeling and Simulation of Surface Roughness in Magnetic Abrasive Finishing Using Non-Uniform Surface Profiles," Materials and Manufacturing Processes, vol. 22/2,
pp. 256 - 270, 2007.
[2] Z. W. Zhong, "Recent Advances in Polishing of Advanced Materials,"
Materials and Manufacturing Processes, vol. 23/5, pp. 449 - 456,2008.
[3] T. Hoshino, Y. Kurata, Y. Terasaki, K. Susa, "Mechanism of polishing
of SiO2 films by CeO2 particles," Journal of Non-Crystalline Solids,
vol. 283, pp. 129-136, 2001.
[4] S.D. Jacobs, D. Golini, Y. Hsu, B.E. Puchebner, D. Strafford, Wm.I. Kordonski, I.V. Prokhorov, E. Fess, D. Pietrowski, V.W. Kordonski,
"Magnetorheological finishing: a deterministic process for optics manufacturing," International Conference on Optical Fabrication and
Testing, 1995, Proc. SPIE 2576, T. Kasai, ed., pp. 372-382.
[5] D. Golini, S.D. Jacobs, W. Kordonski, P. Dumas, "Precision optics
fabrication using magnetorheological finishing," in Advanced Materials
for Optics and Precision Structures, vol. CR67 of SPIE, 1997, pp. 251-274.
[6] W.I. Kordonski, S.D. Jacobs, "Magnetorheological finishing,"
International Journal of Modern Physics B, vol. 10, pp. 2857-
2865,1996.
[7] A.B.Shorey , S.D.Jacobs,W.I. Kordonski ,R.F. Gans , "Experiments and
observations regarding mechanisms of glass removal in magnetorheological finishing," Applied Optics , vol. 40/1, pp. 20-33,2001.
[8] W.Kordonski, D.Golini, P. Dumas, S. Jacobs, "Magnetorheological
suspension-based finishing technology", Proc. SPIE 3326, pp. 527-535, 1998.
[9] Donald Golini, William I Kordonski, Paul Dumas, Steve Hogan,
"Magnetorheological finishing (MRF) in commercial precision optics
manufacturing," Proc. SPIE 3782 conference on optical manufacturing
and testing, pp. 80-90, 1999.
[10] A. Kumar Singh, S. Jha, P.M. Pandey, "Design and development of
nanofinishing process for 3D surfaces using ball end MR finishing
tool," International Journal of Machine Tools & Manufacture, vol. 51,
pp. 142-151, 2011.
[11] S. Jha, V.K. Jain, "Design and development of the magnetorheological
abrasive flow finishing (MRAFF) process," International Journal of
Machine Tools & Manufacture, vol. 44, pp. 1019-1029, 2004.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:53073", author = "Anant Kumar Singh and Sunil Jha and Pulak M. Pandey", title = "Performance Evaluation of Improved Ball End Magnetorheological Finishing Process", abstract = "A novel nanofinishing process using improved ball
end magnetorheological (MR) finishing tool was developed for finishing of flat as well as 3D surfaces of ferromagnetic and non ferromagnetic workpieces. In this process a magnetically controlled
ball end of smart MR polishing fluid is generated at the tip surface of
the tool which is used as a finishing medium and it is guided to
follow the surface to be finished through computer controlled 3-axes
motion controller. The experiments were performed on ferromagnetic
workpiece surface in the developed MR finishing setup to study the effect of finishing time on final surface roughness. The performance
of present finishing process on final finished surface roughness was studied. The surface morphology was observed under scanning
electron microscopy and atomic force microscope. The final surface finish was obtained as low as 19.7 nm from the initial surface
roughness of 142.9 nm. The outcome of newly developed finishing process can be found useful in its applications in aerospace,
automotive, dies and molds manufacturing industries, semiconductor and optics machining etc.", keywords = "Ball end MR finishing tool, Magnetorheological finishing, Nanofinishing", volume = "6", number = "1", pages = "72-5", }