Finite Element Analysis to Study the Magnetic Normal Force in Ball End Type Magnetorheological Finishing Process

Abstract

The developed ball end type magnetorheological finishing process has the advantage to finish a 3D complex shaped surface. The number of carbonyl iron particle chains per active abrasives on the surface of workpiece has been studied. The arrangement of carbonyl iron particles with active abrasives on the surface of workpiece along ball end type magnetorheological finishing tool with hollow core and solid core have been modeled using Maxwell Ansoft V13 (student version). Further, the finite element simulation to find the magnetic normal force on the active particles were carried out during ball end type magnetorheological finishing process having tool with hollow core and solid core. Effects of magnetically induced normal force on the active abrasive particles on workpiece surfaces for ball end type magnetorheological finishing tool with hollow core and solid core has been analyzed by varying the parameters like magnetizing current, working gap and position of electromagnet coil. The performance of both the cases such as tool with hollow core and solid core has been verified. It has been seen that in case of solid core tool the magnitude of magnetically induced normal force on the active abrasive particles with same parameters like working gap, magnetizing current and distance of coil from tool tip surface was found more as compared to hollow core tool. Therefore in case of tool with solid core, the better bonding between carbonyl iron particles along with active abrasives can be achieved even with low magnetizing current during the finishing of workpiece surfaces.