Skip to main content
SpringerLink
Log in

Improved design of magnetorheological honing tool based on finite element analysis and experimental examination of its performance

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The magnetorheological honing (MRH) tool is an advanced finishing tool which is designed and developed to superfinish internal cylindrical surfaces. It uses magnetorheological polishing fluid consisting of carbonyl iron particles and cutting-edge silicon carbide abrasives in viscous fluid medium. The MRH tool with retained polishing fluid is rotated and reciprocated inside a cylindrical workpiece within the gap between the outer surface of the MRH tool and the inner surface of the cylindrical workpiece called the working gap. Due to the relative motion between abrasives (gripped by carbonyl iron particles chains) and the workpiece’s inner surface, finishing action takes place over the inner surface of the cylindrical workpiece. In this paper, two different designs of the MRH tool are designed with the same parameters based on finite element (FE) analysis using Ansoft Maxwell. The FE analysis results in more magnitude and uniformity of magnetic flux density in the working gap for the improved design of the MRH tool. Due to this effect, the abrasives are more strongly held with uniform strength which results in comparatively significant uniform finishing of the internal surface of the cylindrical workpiece. After confirmation of higher and uniform magnetic flux density on the improved MRH tool surface from FE analysis, two designs of the MRH tool are then fabricated with the same dimensions as taken in magnetic simulation. Experimentations have been performed with the fabricated finishing tools over the inner surface of cylindrical ferromagnetic workpiece of mild steel. The MRH tool with improved design results in uniform and more reduction in value of surface roughness with the same finishing time and process parameters as compared to the first proposed design. This confirms the enhancement in the finishing capability and better usefulness of the improved design of the MRH tool.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Jha S, Jain VK (2006) Modeling and simulation of surface roughness in magnetorheological abrasive flow finishing (MRAFF) process. Wear 261:856–866

    Article  Google Scholar 

  2. Grover V, Singh AK (2017) A novel magnetorheological honing process for nano-finishing of variable cylindrical internal surfaces. Material and Manufacturing Processes. https://doi.org/10.1080/10426914.2016.1257801

  3. Wu X, Kita Y, Ikoku K (2007) New polishing technology of freeform surface by GC. J Mater Process Technol 187–188:81–84

    Article  Google Scholar 

  4. Shiou FJ, Chen CH (2003) Freeform surface finish of plastic injection mold by using ball-burnishing process. J Mater Process Technol 140:248–254

    Article  Google Scholar 

  5. Nowicki B (1993) The new method of freeforms surface honing. CIRP Ann Manuf Techn 42:425–428

    Article  Google Scholar 

  6. Cho S, Ryu YK, Lee SY (2002) Curved surface finishing with flexible abrasive tool. Int J Mach Tools Manuf 42:229–236

    Article  Google Scholar 

  7. Shaw MC (1996) Principles of abrasive processing. Clarendon, Oxford

    Google Scholar 

  8. Bedi TS, Singh AK (2016) Magnetorheological methods for nanofinishing—a review. Particul Sci Technol 34(4):412–422

    Article  Google Scholar 

  9. Kordonski WI, Jacobs SD (1996) Magnetorheological finishing. Int J Mod Phys B 10:2857–2865

    Article  Google Scholar 

  10. Das M, Jain VK, Ghoshdastidar PS (2012) Nanofinishing of flat workpiece using rotational-magnetorheological abrasive flow finishing (R-MRAFF) process. Int J Adv Manuf Technol 62:405–420

    Article  Google Scholar 

  11. Jha S, Jain VK (2004) Design and development of the magnetorheological abrasive flow finishing (MRAFF) process. Int J Mach Tools Manuf 44:1019–1029

    Article  Google Scholar 

  12. Singh AK, Jha S, Pandey PM (2011) Design and development of nanofinishing process for 3D surfaces using ball end MR finishing tool. Int J Mach Tools Manuf 51:142–151

    Article  Google Scholar 

  13. Chen M, Liu H, Su Y, Yu B, Fang Z (2016) Design and fabrication of a novel magnetorheological finishing process for small concave surfaces using a ball-end permanent-magnet polishing head. Int J Adv Manuf Technol 83:823–834

    Article  Google Scholar 

  14. Kordonski W, Shorey A (2007) Magnetorheological (MR) jet finishing technology. J Intell Mater Syst Struct 18:1127–1130

    Article  Google Scholar 

  15. Sadiq A, Shunmugam MS (2009) Investigation into magnetorheological abrasive honing (MRAH). Int J Mach Tools Manuf 49:554–560

    Article  Google Scholar 

  16. Wang J, Chen W, Han F (2015) Study on the magnetorheological finishing method for the WEDMed pierced die cavity. Int J Adv Manuf Technol 76:1969–1975

    Article  Google Scholar 

  17. Sidpara A, Jain VK (2012) Experimental investigations into surface roughness and yield stress in magnetorheological fluid based nano-finishing process. Int J Adv Manuf Technol 13(6):855–860

    Google Scholar 

  18. Niranjan MS, Jha S (2015) Experimental investigation into tool aging effect in ball end magnetorheological finishing. Int J Adv Manuf Technol 80:1895–1902

    Article  Google Scholar 

  19. Martínez-Mateo, I. (2011) Surface damage of mould steel and its influence on surface roughness of injection moulded plastic parts. 18th International Conference on Wear of Materials 271: 2512–2516

  20. Gupte PS, Wang Y, Miller W, Barber GC, Yao C, Zhou B, Zou Q (2008) A study of torn and folded metal (TFM) on honed cylinder bore surfaces. Tribol Trans 51:784–789

    Article  Google Scholar 

  21. Jain VK (2008) Abrasive-based nano-finishing techniques: an overview. Mach Sci Technol 12:257–294

    Article  Google Scholar 

  22. Stradling AW (1993) The physics of open-gradient dry magnetic separation. Int J Miner Process 39:19–29

    Article  MathSciNet  Google Scholar 

  23. Grover V, Singh AK (2017) Analysis of particles in magnetorheological polishing fluid for finishing of ferromagnetic cylindrical workpiece. Particul Sci Technol. https://doi.org/10.1080/02726351.2017.1302535

Download references

Funding

The authors acknowledge the Science and Engineering Research Board, Department of Science and Technology, New Delhi, India, (Project no. EMR/2015/000330) for their financial support.

Author information

Authors and Affiliations

  1. Mechanical Engineering Department, Thapar University, Patiala, 147004, India

    Vishwas Grover & Anant Kumar Singh

Authors
  1. Vishwas Grover
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Anant Kumar Singh
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Anant Kumar Singh.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Grover, V., Singh, A.K. Improved design of magnetorheological honing tool based on finite element analysis and experimental examination of its performance. Int J Adv Manuf Technol 100, 1067–1080 (2019). https://doi.org/10.1007/s00170-017-1149-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-017-1149-5

Keywords

Search

Navigation