ABSTRACT
A finishing tool with magnetorheological polishing fluid arrangement is developed for nanofinishing of an external cylindrical surface of non-ferromagnetic components such as brass, aluminium, and so on. In this, the tool consists of permanent magnets, which have the advantage of being flexible according to the cylindrical dimension of work material. Because of simple design of tool structure, this entire set is called low-cost magnetorheological finishing process. The design of experiments is conducted using response surface methodology where the effect of various process variables – workpiece rotational speeds (400 rpm, 600 rpm and 800 rpm), tool linear speed (10 cm/min, 30 cm/min and 50 cm/min), mesh sizes of SiC abrasives (600, 800 and 1000) and mesh sizes of EIPs (200, 300 and 400) are taken for evaluating the percentchange in surface roughness Ra value. The results concluded that the highestpercentageof roughness change is found on a brass workpiece with workpiece rotational speed of 600 rpm, tool linear speed of 10 cm/min, 800 mesh size SiC and 300 mesh size of EIPs. The lowestRa value is found as 97 nm from 361 nm with 40 min of finishing and a 1 mm working gap.
