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.