LAUSR

ABSTRACT A rotating core-based magnetorheological finishing process has been developed to finish the external cylindrical surfaces at the nano-level more efficiently. The existing MR finishing process based on the stationary curved core tool tip is found to be comparatively less effective than the present process based on a rotating flat core tool tip for finishing the external cylindrical surfaces. This is due to the fact that in the present process both the workpiece and the tool rotating rather than giving rotation to the workpiece alone as in the existing process. The carbonyl iron particle (CIP) chains are rotated along with the rotation of the tool. This results in an increase in the kinetic energy of the active abrasive particles gripped by CIP chains which causes for the better finishing performance. Finishing is done by both the processes and their corresponding results are compared. The Ra, Rq, and Rz values are reduced to 71.62%, 72.53%, and 70.73% with a stationary curved core tool tip, and 94.59%, 94.51%, and 92.68% with a rotating flat core tool tip in 90 minutes of MR finishing. The overall results revealed that the present developed process using the rotating flat tool tip is more useful in finishing the external cylindrical surfaces as compared to the stationary curved tool tip.