Date:11/02/2019

Presentation Topic:-
“MAGNETORHEOLOGICAL MACHINING PROCESS”

for
Course Name : Advanced Manufacturing Technology – II for Industrial Infrastructure
Guided By : Dr. Navneet Khanna

Presented By:-
Mahesh Bharati
 INTRODUCTION
• Surface quality is one of the most important properties of the
precision devices. [1]

• Poor surface quality of engineering products results in various

problems during operations, such as malfunctioning, excessive
wear, geometric inaccuracy, etc.[1]

• Magnetorheological fluid assisted finishing processes are one

such kind of finishing processes, which has greater flexibility
towards process control and one can finish with close
tolerances and without damaging surface topography.[1]

[1] Magnetorheological Finishing: A Review by K.Saraswathamma, Mechanical Engineering Department, Osmania

University, Hyderabad, India. Accepted 10 January 2014,Published in IJCET.
• The traditional abrasive finishing (grinding, lapping, honing)
processes generally employ a rigid tool that subjects the
component to substantial normal stresses which causes micro-
cracks on surface or subsurface resulting in reduced strength
and reliability of the component.[2]

• EDM, ECM, USM, AJM etc. has a major limitation in

finishing complex geometries due to the lack of control over
the finishing forces and moreover sometimes these processes
impart surface and subsurface damages.[1]

[2] T.Hoshino,Y.Kurata,Y.Terasaki,K.Susa,Mechanism of polishing of SiO2 films by CeO2 particles, Journal of Non-

Crystalline Solids 283 (2001) 129–136.
[1] [Magnetorheological Finishing: A Review by K.Saraswathamma, Mechanical Engineering Department, Osmania
University, Hyderabad, India. Accepted 10 January 2014,Published in IJCET.
• Many newly developed Magnetorheological fluid assisted
finishing processes make use of magnetorheological fluid (MR
fluid) to externally control the finishing forces on abrasive
particles.[1]

• Few of them are

– Magnetorheological finishing (MRF),
– Magnetorheological jet finishing (MRJF),
– Magnetorheological abrasive flow finishing (MRAFF),
– Magnetorheological abrasive honing (MRAH)
– Ball end magnetorheological finishing (BEMRF).
[1] Magnetorheological Finishing: A Review by K.Saraswathamma, Mechanical Engineering Department, Osmania
University, Hyderabad, India. Accepted 10 January 2014,Published in IJCET.
• Magnetorheological finishing is a super/nano finishing process that
has been applied to a large variety of brittle materials, ranging from
optical glasses to hard crystals.

• MRF is a precision technology that may produce surface accuracy

on the order of 30nm peak to valley and surface micro-roughness
less than 10Å rms [1].Also, it can operate with 5 degree of freedom.

• All magnetorheological finishing processes relies for its

performance on magnetorheological fluid.

• The magnetorheological fluid are termed smart fluid because it

exhibits change in rheological property under influence of magnetic
fluid, which in turn helps to precisely control finishing forces to
control surface quality.[3]

[3]Amir Dehghan Ghadikolaei and Mehrdad Vahdati, Experimental study on the effect of finishing parameters on surface
roughness in magnetorheological abrasive flow finishing process, JEM IMechE 2014
 Fig. The 5-axis Q22-Y developed in 2000 added the Y-axis[4]

[4] Daniel C. Harris, “History of Magnetorheological Finishing”, Proceedings of SPIE, 2011

 MAGNETORHEOLOGICAL FLUID
• The strength of this fluid directly depends on the
magnetic field and magnetic particles dispersed in the
medium.
• After applying an external field, their behaviour change
from being Newtonian to Bingham plastic.
• Magnetorheological fluid and its composition are crucial
in MRF processes.
• There are basically four components in an MR fluid :
– Base fluid
– Metal particles
– Abrasive particles
– Stabilizing additives.
• BASE FLUID:
– The base fluid is an inert or non magnetic carrier fluid in
which the metal particles are suspended.
– E.g. Water , hydrocarbon oils, mineral oils and Silicon oils ,
glycols
• METAL PARTICLES:
– Carbonyl iron, Powder iron and Iron Cobalt alloy powder
• ABRASIVE PARTICLES:
– Silicone carbide, Aluminium oxide, Cerium oxide, Boron
carbide
• STABILIZING ADITIVES:
– Glycerol, Grease, Oleic acid, Xanthanum gum, Ferrous
oleate , Lithium stearate, silica nanoparticles, carbon
fibbers, polymers
 DESIRABLE PROPERTY OF MR FLUIDS

• High yield stress under magnetic field

• Low off-state viscosity
• Less agglomeration and good redispersibility
• Temperature-stable
• Resistance to corrosion
• Stability against static sedimentation
• High polishing efficiency
• The viscosity of base fluid should be temperature stable in a
predefined range.
 (a) (b)
Fig. Chain formation in magnetorheological polishing fluid,
a) Abrasives & Carbonyl iron particles at zero magnetic fields;
b) Abrasive particles embedded in Carbonyl iron particle chains on
application of external magnetic field.[4]
[4] Sunil Jha, V.K. Jain,” Design and development of the magnetorheological abrasive flow finishing (MRAFF) process”, Department
of Mechanical Engineering, Indian Institute of Technology, Kanpur , India International Journal of Machine Tools & Manufacture 44
(2004) 1019–1029
Fig. (a) CIP and abrasive particles randomly dispersed in carrier medium in the absence of magnetic
field. (b) CIP aligned in chain form when magnetic field is applied.[5]

Fig. Jet snapshot images ,velocity=30 m/s, nozzle diameter=2 mm[1]

[1] Magnetorheological Finishing: A Review by K.Saraswathamma, Mechanical Engineering Department, Osmania University,
Hyderabad, India. Accepted 10 January 2014,Published in IJCET
[5] Dilshad Ahmad Khan & Sunil Jha, “Selection of optimum polishing fluid composition for ball end magnetorheological
finishing (BEMRF) of copper”, IJAMT, September 2017
 OPERATION MODE

• Flow mode [6]

• Shear mode

• Squeeze-flow mode
[6] Wang, Hong-yun; Zheng, Hui-qiang; Li, Yong-
xian; Lu, Shuang, “Mechanical properties of
magnetorheological fluids under squeeze-shear
mode“.
 MR FLUID BEHAVIOUR

Fig. Variation of yield stress with CIP grades[6]

Fig. Variation of viscosity with CIP grades[6]

[7] K. Saraswathamma, Sunil Jha & P. Venkateswara Rao, “Rheological Characterization of MR Polishing Fluid Used for Silicon
Polishing in BEMRF Process”, Materials and Manufacturing Processes, 30: 661–668, 2015 ,Copyright _Taylor & Francis Group,
LLC
 BASIC PRINCIPLE

• Fig. Mechanism of material removal in BEMRF process (a) gripped active abrasive particle with CIPs
chains approaching initial roughness peaks of the work piece surface, (b) updated roughness peaks after
removing the first layer in the form of micro chips and (c) final roughness peaks after removing the almost
all its layers in the form of micro-chips.[8]

• Fig. Schematic representation of material removal by gripped active abrasive particle with CIPs chains in
BEMRF process (a) without any feed rate on work piece and (b) with feed rate on the work piece.[8]
 Fig. MRP-fluid layer in the working gap between the surfaces of tool tip and work piece.[6]

Fig. (a) Possible arrangement of two chains of CIPs with 3 active abrasives on the work piece surface and (b)
Forces applied by a single CIPs chain on active SiC abrasives. [8]

[8] Anant Kumar Singh,Sunil Jha , Pulak M.Pandey , “Mechanism of material removal in ball end magnetorheological finishing
process “, Wear 302 (2013) 1180–1191
Fig. Schematic of ball end MR finishing tool[5] Fig. Schematic of flow of magnetic flux in BEMRF
process[8]

[5] Dilshad Ahmad Khan & Sunil Jha, “Selection of optimum [8] Anant Kumar Singh,Sunil Jha , Pulak M.Pandey ,
polishing fluid composition for ball end magnetorheological “Mechanism of material removal in ball end
finishing (BEMRF) of copper”, IJAMT, September 2017 magnetorheological finishing process “, Wear 302 (2013)
1180–1191
 FORCE ANALYSIS

• Two type of forces act on an abrasive particle

• Normal Force(Fn)-
– penetration of abrasive inside the work piece.
– Due to magnetic levitation force by magnetic particles and
squeeze during flow in converging gap.
– Presses abrasive against work piece.
• Tangential Force(Ft)
- removal of material in form of micro / nano chips.
- By the shear flow of MR fluid.
- Pushes abrasive forward.
• The resultant force (Fr)
– removes material from work piece.
Fig. Interaction of abrasive particle with work piece surface due to repulsion by a high gradient magnetic
field[8].

Fig. Comparison of experimental and theoretical results for Fn at different working gap.[7]

[8] Anant Kumar Singh,Sunil Jha , Pulak M.Pandey , “Mechanism of material removal in ball end magnetorheological finishing
process “, Wear 302 (2013) 1180–1191
 PARAMETER ANALYSIS

[3] Amir Dehghan Ghadikolaei and Mehrdad Vahdati, Experimental study on the effect of finishing parameters on surface roughness in
magnetorheological abrasive flow finishing process, JEM IMechE 2014
 LIMITATION

• High-quality fluids are expensive.

• Fluids are subject to thickening after prolonged use and need
replacing.
• Settling of ferro-particles can be a problem for some
applications.
 SCOPE OF FUTURE WORK

• Surface like sphere can not be finished by existing setup and

6th axis can be integrated to finish more complex geometry.
• Requirement of a mechanism to reduce the temperature of the
coil while applying high current so that continuous finishing
can be done for longer period of time
 APPLICATION
• Nano-finishing of Ti6Al4V flat [9].
• Ultra precision polishing of Si3N4 ceramics

Source : https://qedmrf.com/en/mrfpolishing/mrf-applications
Source : https://qedmrf.com/en/mrfpolishing/mrf-applications
 REFRENCES
[1] Magnetorheological Finishing: A Review by
K.Saraswathamma, Mechanical Engineering Department,
Osmania University, Hyderabad, India. Accepted 10 January
2014,Published in IJCET

[2] T.Hoshino,Y.Kurata,Y.Terasaki,K.Susa,Mechanism of
polishing of SiO2 films by CeO2 particles, Journal of Non-
Crystalline Solids 283 (2001) 129–136.

[3] Amir Dehghan Ghadikolaei and Mehrdad Vahdati,

Experimental study on the effect of finishing parameters on
surface roughness in magnetorheological abrasive flow finishing
process, JEM IMechE 2014

[4] Sunil Jha, V.K. Jain,” Design and development of the

magnetorheological abrasive flow finishing (MRAFF) process”,
Department of Mechanical Engineering, Indian Institute of
Technology, Kanpur , India International Journal of Machine
Tools & Manufacture 44 (2004) 1019–1029
[5] Dilshad Ahmad Khan & Sunil Jha, “Selection of optimum
polishing fluid composition for ball end magnetorheological
finishing (BEMRF) of copper”, IJAMT, September 2017

[6] Wang, Hong-yun; Zheng, Hui-qiang; Li, Yong-xian; Lu,

Shuang, “Mechanical properties of magnetorheological fluids
under squeeze-shear mode

[7] K. Saraswathamma, Sunil Jha & P. Venkateswara Rao,

“Rheological Characterization of MR Polishing Fluid Used for
Silicon Polishing in BEMRF Process”, Materials and
Manufacturing Processes, 30: 661–668, 2015 ,Copyright _Taylor
& Francis Group, LLC

[8] Anant Kumar Singh,Sunil Jha , Pulak M.Pandey ,“Mechanism

of material removal in ball end magnetorheological finishing
process “, Wear 302 (2013) 1180–1191
[9] Parameswari, G., Jain, V. K., Ramkumar, J., & Nagdeve, L.
(2017). Experimental investigations into nanofinishing of
Ti6Al4V flat disc using magnetorheological finishing process.
International Journal of Advanced Manufacturing Technology, 1–
11. https://doi.org/10.1007/s00170-017-1191-3