An overview of magnetorheological polishing fluid applied in nano-finishing of components

Abstract

Surface quality is the most crucial factor affecting the product lifespan and performance of any component. Most earlier technologies display accuracy in the micrometre or submicrometre range, surface roughness in the nanometre range, and almost no surface defects in the production of optical, mechanical and electronic parts. Such finishing methods incorporate a magnetic field to control the finishing forces using magnetorheological fluid as the polishing medium. Magnetorheological fluid (MR) consists of ferromagnetic and abrasive particles. It is a type of modern intelligent fluid. An optimum selection of magnetorheological fluid constituents and their volume concentration plays an essential role for the ultra-fine finishing of newly developed engineering products. Rheological characteristics of magnetorheological fluid can change rapidly and effortlessly with the support of an activated magnetic field. Traditional finishing methods are comparatively inferior in finishing complex freeform surfaces, due to the lack of controlling finishing forces and limitations of polishing tool movement over the complex freeform contour of the components. There are different types of processes based on the magnetorheological fluid including magnetorheological finishing, magnetorheological abrasive flow finishing, rotational magnetorheological abrasive flow finishing and ball end magnetorheological finishing. This article discusses the development of different types of magnetorheological-fluid-based finishing processes and their modes of operation. The MR fluid devices developed in the last decade are thoroughly reviewed for their working principles, characteristics and applications. This article also highlights the study of rheological characterization of magnetorheological fluid and its applications in different polishing methods appropriate for finishing various complex freeform components.

RETRACTED ARTICLE: Minimization of Surface Roughness and Residual Stress in Grinding Operations of Inconel 718

“…The mechanical, thermal, and chemical effects in metal cutting operations which produce chips can generate residual stress in the machined components (Ref 2). Residual stress as well as surface integrity of machined components are the most important factors which affect the dependability, accuracy, and lifespan of finished parts ( Ref 3,4). The working life of parts can be decreased by reducing the fatigue life due to enhancement of the final residual stress as well as surface roughness in the produced parts which can reduce the productivity of the manufacturing process.…”

Magnetorheological finishing of aluminium cylindrical roller for enhanced performance of printing operation

“…This occurs when the active abrasives' shear force exceeds the resistant shear force given by the roughness peaks of the work-part material. 23…”

“…This is because the carrier fluid makes the active abrasive brush much more flexible, increasing its finishing capacity. [23][24][25] This flexible abrasive brush causes the consistency in the finishing of workpiece materials. 26 Therefore, now a days researchers are continuously working on the MR finishing process for exploring its capability to finish the varieties of real time industrial components based on materials, shapes, sizes, requirement of level of finishing, precision etc.…”

Study of machining parameters in reciprocating magnetorheological polishing process based on response surface methodology

“…Magnetorheological polishing (MRP) is a kind of ultraprecision machining technology to remove materials on workpiece surface by using the magnetorheological effect of magnetorheological polishing fluids (MRP fluids) in a magnetic field (Kumar et al , 2021; Wang et al , 2021; Xiu et al , 2018; Sidpara and Jain, 2011). It is different from traditional polishing technologies, such as chemical mechanical polishing (CMP) (Liao et al , 2021).…”