Modeling and Simulation of Surface Roughness in Improved Magnetorheological Honing Process

Abstract

A novel improved magnetorheological honing process is developed for finishing of internal geometries of ferromagnetic cylindrical workpiece as existing magnetorheological fluid based finishing processes are not found suitable to finish the internal surface of cylindrical ferromagnetic components. The performance of finishing action to enhance material removal in the developed process mainly depends on the normal force acting on abrasive particles due to magnetic behavior of the carbonyl iron particles with magnetic field in magnetorheological polishing fluid. Also, it depends on the shear force acting on surface by abrasive particles due to translational and rotational motion of tool as likely similar to the honing operation. In the present work, modeling of magnetic field induced in magnetorheological finishing fluid and the surface roughness values with the effect of finishing cycles have been done. To validate the model and understand the material removal mechanism during finishing in improved magnetorheological honing process, the experiments have been performed on the internal surface of cylindrical ferromagnetic workpiece with the three different sets of finishing cycles. The surface roughness of cylindrical workpiece has experimentally measured with Mitutoyo SJ-400 surftest and to understand material removal mechanism during finishing of the workpiece surface, the scanning electron microscopy has been also performed. The theoretical induced magnetic field in magnetorheological finishing fluid and surface roughness with number of finishing cycles were calculated. The calculated values were validated with experimentally for the same number of finishing cycles and conditions. The theoretical calculated surface roughness values with the number of finishing cycles have been compared with the experimental obtained surface roughness values. Both were found in close agreement within 4.54 %. Thus, the present improved magnetorheological finishing process is found suitable for finishing of internal surface of cylindrical ferromagnetic components which leads to the functional applications of cylindrical ferromagnetic components as compared to traditional finishing techniques.