Development of continuous flow magnetorheological fluid finishing process for finishing of small holes

  • Mukul Kataria
  • S. K. MangalEmail author
Technical Paper


The objective of the present experimental study is to find competency of magnetorheological fluid finishing process in improving the finishing and dimensional accuracy of miniature holes drilled by the electro-discharge drilling process. For this, holes of 2.0 mm diameter, drilled in aluminium 6063 alloy-based metal matrix composite, is finished using indigenously developed magnetorheological fluid finishing set-up. The input parameters of the process, viz. supply current, MR fluid flow rate, finishing time and pole geometry, are optimized for machining characteristics, viz. average surface roughness height (Ra, µm) and Taper (TAP, degree). Experiments are carried out which are based on the Taguchi experimental design L16 orthogonal array. Grey relational analysis (GRA) is further carried out to obtain the combination of the input machining parameters for optimizing both the response characteristics simultaneously. From GRA, it is found that higher values of supply current, fluid flow rate and finishing time with flat pole geometry have generated optimal machining performance characteristics and the most influential controllable factor is the finishing time. Microscopic analysis is performed using field emission scanning electron microscope and atomic force microscope on the surfaces of holes before and after MR fluid finishing operation. The results have shown that the developed MR fluid-based finishing process significantly enhances the characteristics of holes. The surface roughness from a region of unfinished hole is found to be 5.4 µm, whereas it is in nm range for the finished surface.


Magnetorheological finishing fluid Holes Surface roughness Taperness Grey relational analysis 



The authors acknowledge the contributions of Production and Industrial Engineering Department, Punjab Engineering College, Chandigarh; Sophisticated Analytical Instrumentation Facility, Panjab University Chandigarh and National Institute of Technical Teacher Training and Research, Chandigarh, for providing their laboratory facilities.


  1. 1.
    Benes J (2000) Hole making trends run deep, fast and dry. AmMach 144:97–104Google Scholar
  2. 2.
    Kumar R, Singh I, Kumar D (2013) Electro discharge drilling of hybrid MMC. Procedia Eng 64:1337–1343CrossRefGoogle Scholar
  3. 3.
    Unune DR, Nirala CK, Mali HS (2018) Accuracy and quality of micro-holes in vibration assisted micro-electro-discharge drilling of Inconel 718. Measurement 135:424–437CrossRefGoogle Scholar
  4. 4.
    Sambharia J, Mali HS (2019) Recent developments in abrasive flow finishing process: a review of current research and future prospects. Proc IMechE Part B J Eng Manuf 233:388–399CrossRefGoogle Scholar
  5. 5.
    Pachaury Y, Tandon P (2017) An overview of electric discharge machining of ceramics and ceramic based composites. J Manuf Process 25:369–390CrossRefGoogle Scholar
  6. 6.
    Murugesan S, Balamurugan K (2012) Optimization by grey relational analysis of EDM parameters in machining Al-15% SiC MMC using multi-hole electrode. J Appl Sci 12:963–970CrossRefGoogle Scholar
  7. 7.
    Lin YC, Chow HM, Yan BH, Tzeng HJ (2007) Effects of finishing in abrasive fluid machining on microholes fabricated by EDM. Int J Adv Manuf Technol 33:489–497CrossRefGoogle Scholar
  8. 8.
    Das M, Jain VK, Ghoshdastidar PS (2010) Nano-finishing of stainless-steel tubes using rotational magnetorheological abrasive flow finishing process. Mach Sci Technol 14:365–389CrossRefGoogle Scholar
  9. 9.
    Parameswari G, Jain VK, Ramkumar J, Nagdeve L (2017) Experimental investigations into nanofinishing of Ti6Al4 V flat disc using magnetorheological finishing process. Int J Adv Manuf Technol 93:1–11CrossRefGoogle Scholar
  10. 10.
    Singh AK, Jha S, Pandey PM (2015) Performance analysis of ball end magnetorheological finishing process with MR polishing fluid. Mater Manuf Processes 30:1482–1489CrossRefGoogle Scholar
  11. 11.
    Singh GD, Singh AK, Garg P (2017) Development of magnetorheological finishing process for external cylindrical surfaces. Mater Manuf Processes 32:581–588CrossRefGoogle Scholar
  12. 12.
    Maan S, Singh G, Singh AK (2017) Nano-surface finishing of permanent mold punch using magnetorheological fluid-based finishing processes. Mater Manuf Processes 32:1004–1010CrossRefGoogle Scholar
  13. 13.
    Barman A, Das M (2018) Nano-finishing of bio-titanium alloy to generate different surface morphologies by changing magnetorheological polishing fluid compositions. Precis Eng 51:145–152CrossRefGoogle Scholar
  14. 14.
    Ghai V, Ranjan P, Batish A, Singh H (2018) Atomic-level finishing of aluminum alloy by chemo-mechanical magnetorheological finishing (CMMRF) for optical applications. J Manuf Process 32:635–643CrossRefGoogle Scholar
  15. 15.
    Mangal SK, Sharma V (2017) Multi-parameter optimization of magnetorheological fluid with high on-state yield stress and viscosity. J Braz Soc Mech Sci Eng 39:4191–4206CrossRefGoogle Scholar
  16. 16.
    Mangal SK, Kataria M (2018) Characterization of magnetorheological finishing fluid for continuous flow finishing process. J Appl Fluid Mech 11:1751–1763CrossRefGoogle Scholar
  17. 17.
    Jiang B, Zhenglong L, Xi C, Peng L, Nannan L, Yanbin C (2018) Microstructure and mechanical properties of TiB2-reinforced 7075 aluminum matrix composites fabricated by laser melting deposition. Ceram Int 45:5680–5692CrossRefGoogle Scholar
  18. 18.
    Patel KM, Pandey PM, Rao PV (2010) Optimisation of process parameters for multi-performance characteristics in EDM of Al2O3 ceramic composite. Int J Adv Manuf Technol 47:1137–1147CrossRefGoogle Scholar
  19. 19.
    Kataria M, Mangal SK (2018) Characterization of aluminium metal matrix composite fabricated by gas injection bottom pouring vacuum multi-stir casting process. Kovove Mater 56:231–243Google Scholar

Copyright information

© The Brazilian Society of Mechanical Sciences and Engineering 2019

Authors and Affiliations

  1. 1.Dr SS Bhatnagar University Institute of Chemical Engineering and TechnologyPanjab UniversityChandigarhIndia
  2. 2.Mechanical Engineering DepartmentPunjab Engineering CollegeChandigarhIndia

Personalised recommendations