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

  • Vishwas Grover
  • Anant Kumar SinghEmail author


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.


Magnetorheological Honing Polishing Fluid Surface roughness Carbonyl iron particles 


Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.


Funding information

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.


  1. 1.
    Jha S, Jain VK (2006) Modeling and simulation of surface roughness in magnetorheological abrasive flow finishing (MRAFF) process. Wear 261:856–866CrossRefGoogle Scholar
  2. 2.
    Grover V, Singh AK (2017) A novel magnetorheological honing process for nano-finishing of variable cylindrical internal surfaces. Material and Manufacturing Processes.
  3. 3.
    Wu X, Kita Y, Ikoku K (2007) New polishing technology of freeform surface by GC. J Mater Process Technol 187–188:81–84CrossRefGoogle Scholar
  4. 4.
    Shiou FJ, Chen CH (2003) Freeform surface finish of plastic injection mold by using ball-burnishing process. J Mater Process Technol 140:248–254CrossRefGoogle Scholar
  5. 5.
    Nowicki B (1993) The new method of freeforms surface honing. CIRP Ann Manuf Techn 42:425–428CrossRefGoogle Scholar
  6. 6.
    Cho S, Ryu YK, Lee SY (2002) Curved surface finishing with flexible abrasive tool. Int J Mach Tools Manuf 42:229–236CrossRefGoogle Scholar
  7. 7.
    Shaw MC (1996) Principles of abrasive processing. Clarendon, OxfordGoogle Scholar
  8. 8.
    Bedi TS, Singh AK (2016) Magnetorheological methods for nanofinishing—a review. Particul Sci Technol 34(4):412–422CrossRefGoogle Scholar
  9. 9.
    Kordonski WI, Jacobs SD (1996) Magnetorheological finishing. Int J Mod Phys B 10:2857–2865CrossRefGoogle Scholar
  10. 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 62:405–420CrossRefGoogle Scholar
  11. 11.
    Jha S, Jain VK (2004) Design and development of the magnetorheological abrasive flow finishing (MRAFF) process. Int J Mach Tools Manuf 44:1019–1029CrossRefGoogle Scholar
  12. 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 51:142–151CrossRefGoogle Scholar
  13. 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 83:823–834CrossRefGoogle Scholar
  14. 14.
    Kordonski W, Shorey A (2007) Magnetorheological (MR) jet finishing technology. J Intell Mater Syst Struct 18:1127–1130CrossRefGoogle Scholar
  15. 15.
    Sadiq A, Shunmugam MS (2009) Investigation into magnetorheological abrasive honing (MRAH). Int J Mach Tools Manuf 49:554–560CrossRefGoogle Scholar
  16. 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 76:1969–1975CrossRefGoogle Scholar
  17. 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):855–860Google Scholar
  18. 18.
    Niranjan MS, Jha S (2015) Experimental investigation into tool aging effect in ball end magnetorheological finishing. Int J Adv Manuf Technol 80:1895–1902CrossRefGoogle Scholar
  19. 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: 2512–2516Google Scholar
  20. 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 51:784–789CrossRefGoogle Scholar
  21. 21.
    Jain VK (2008) Abrasive-based nano-finishing techniques: an overview. Mach Sci Technol 12:257–294CrossRefGoogle Scholar
  22. 22.
    Stradling AW (1993) The physics of open-gradient dry magnetic separation. Int J Miner Process 39:19–29MathSciNetCrossRefGoogle Scholar
  23. 23.
    Grover V, Singh AK (2017) Analysis of particles in magnetorheological polishing fluid for finishing of ferromagnetic cylindrical workpiece. Particul Sci Technol.

Copyright information

© Springer-Verlag London Ltd. 2017

Authors and Affiliations

  1. 1.Mechanical Engineering DepartmentThapar UniversityPatialaIndia

Personalised recommendations