Study of machining parameters in reciprocating magnetorheological polishing process based on response surface methodology

Purpose This paper aims to analyze the significance of machining parameters (workpiece’s rotational speed, magnet coil current and working gap) on final Ra (surface roughness) and material removal rate (MRR) of workpiece in reciprocating magnetorheological polishing (RMRP) process. Design/methodology/approach The research is planned to analyze, model and predict the optimum machining parameters to anticipate final Ra and MRR by applying response surface methodology (RSM) and multiresponse optimization (desirability function approach). The experiments have been planned by design of experiments (DOE). Analysis of variance (ANOVA) is applied to determine the significances of machining parameters on RMRP performance characteristics. Findings Response surface plots for final Ra and MRR by RSM show that machining parameters are significant for the responses. The optimum machining parameters obtained are optimized by desirability function approach (DFA), and the optimum parametric combination has been validated by confirmatory experiments. The experimental results of the final Ra and MRR are deviated by 5.12% and 2.31% from the response results under the same optimization conditions, respectively. Originality/value In this study, the RMRP responses (final Ra and MRR) are improved at predicted input machining parameters condition obtained by RSM and DFA approach. Furthermore, the research results provide a reference for experimental design and optimization of MRP process.