Multiple Application of Magnetorheological Effect in High Precision Finishing

Magnetorheological finishing (MRF) is enabling technology that may produce surface accuracy of the order of 10 nm peak-to-valley and surface micro-roughness less than 10A. In this technique, magnetorheological fluid performs the primary function, which is deterministic material removal. There are several auxiliary devices that also function on a “smartness” of magnetorheological fluid. A non-intrusive magnetorheological valve is an integral part of the finishing machine “circulatory system” and provides the pump “stiffness” and computer control of the flow rate. To provide MR polishing fluid continuous circulation, a special means for fluid removal from the polishing wheel and returning to the delivery system has been designed. Once the fluid leaves the polishing zone, it is removed from the wheel surface by a suction cup. The cup has a magnetic system that forms a dynamic magnetorheological fluid seal in the gap between the cup and the wheel surface. Finite element analysis software has been used for magnetic systems and flow design and optimization.