Finite element analysis and mathematical modeling of a novel magnetorheological honing process

Abstract

Magnetorheological honing process has been developed for superfinishing of internal surface of cylindrical objects. This process uses magnetorheological polishing fluid to finish the surfaces. Under the influence of magnetic field carbonyl iron particles along with silicon carbide particles present in magnetorheological fluid performs the finishing operation. The performance of finishing action depends on normal force acting on silicon carbide particles which are on workpiece surface. The normal force exerting on silicon carbide particles makes them to intend in workpiece surface and performs finishing on surfaces due to the shear action. Normal force exerting on silicon carbide particles is due to carbonyl iron particles present in magnetorheological fluid under the influence of external magnetic field. In this ME thesis a novel magnetorheological honing tool has been modeled and finite element analysis of magnetorheological honing tool has been done with the help of Maxwell ANSOFT V13 (student version) software. Magnetorhological honing tool dimensions have been optimized on the basis of finite element analysis for magnetic flux density distribution along with workpiece surfaces. Mathematical modeling of magnetically induced forces acting on silicon carbide abrasive particles along with carbonyl iron particles has also been done. Theoretical calculated value of forces on silicon carbide particles along with carbonyl particles has been compared with the value of forces obtained from finite element simulation results in Maxwell ANSOFT V13 software. Value of forces from both (theoretical and finite element analysis) was found in good agreement. Tool dimensions have been finalized for the fabrication as per the optimized value of dimensions obtained from finite element analysis for maximum flux density distribution of in magnetorheological honing tool with workpiece surfaces. The distributions of magnetic flux density gradient were also analyzed in magnetorheological polishing fluid layer between outer tool finishing surface and workpiece surface and it has been found that outer finishing tool surface has maximum flux density gradient and workpiece surface has low flux density gradient. Hence it shows that magnetorheological polishing fluid always retain on the finishing tool surface as it has maximum flux density gradient. This is one of the important requirements to get finishing on any type of workpiece surfaces such as ferromagnetic and non-ferromagnetic materials. Mathematical modeling of magnetically induced normal forces predicts a way to analyze the forces required for finishing action at different process parameters.