ABSTRACT
Ball end magnetorheological finishing (BEMRF) process requires an electromagnet to precisely control the magnetic field and consequently the forces during the finishing action. The heat generated in electromagnet in the BEMRF tool, pose thermal management issues, which restricts the maximum current supply in the tool. For better finishing process, higher magnetic field strength is desirable, which is directly proportional to the current supplied in the electromagnet. The BEMRF tool uses the direct liquid system, for which the maximum current supplied in the coil is limited up to 8 A, after which the coil damages due to heat. The objective 200of this chapter is to understand the thermal path, hotspot, and effectiveness of the cooling system, based on which further design modifications can be suggested. Entry of fluid in the direction normal to the cylindrical coil causes fluid structure near inlet region to achieve non-uniform heat dissipation, therefore need arises to modify the inlet port. A comparison case without gaps, is simulated to check the claim, that even, negligible flow rate may improve overall working condition of electromagnet. Based on the analysis of results, some improvements are suggested for the design of the cooling system.
