Magnetorheological finishing of an irregular-shaped small-bore complex component using a small ball-end permanent-magnet polishing head

A novel magnetorheological finishing(MRF)process using a small ball-end permanent-magnet polishing head is proposed,and a four-axes linkage dedicated MRF machine tool is fabricated to achieve the nanofinishing of an irregularψ-shaped small-bore complex component with concave surfaces of a curvature radius less than3 mm.The processing method of the complex component is introduced.Magnetostatic simulation during the entire finishing path is carried out to analyze the material removal characteristics.A typicalψ-shaped small-bore complex component is polished on the developed device,and a fine surface quality is obtained with surface roughness Raof 0.0107μm and surface accuracy of the finished spherical surfaces of 0.3320μm(PV).These findings indicate that the proposed MRF process can perform the nanofinishing of a kind of small-bore complex component with small-curvature-radius concave surfaces.

Magnetorheological finishing of low-gradient curved surfaces based on four-axis linkage technique

Based on the distribution characteristic of magnetic field along the polish wheel,the four-axis linkage technique is advanced to replace a standard five-axis one to figure low-gradient optical surfaces with a raster tool-path in magnetorheological finishing(MRF).After introducing the fundaments of such simplification,the figuring reachability of a four-axis system for the low-gradient optics was theoretically analyzed.Further validation including magnetic field intensity and influence function characteristic was performed to establish its application.To demonstrate the correctness,feasibility and applicability of such technique,a K4 spherical part was figured by two iterations of MRF with surface form error improved to 0.219λPV and 0.027λRMS.Meanwhile,the surface roughness was also improved a lot in MRF process.These theoretical analyses and experimental results both indicate that high form accuracy and excellent surface quality can be obtained by using the four-axis linkage technique in the process of figuring low-gradient optical elements,and the four-axis linkage system undoubtedly is much more easy to control and much more economical.

The Synthetic Effect of Magnetorheological Finishing Technology:Analysis,Modeling,and Control

The controllable key factors in magnetorheological finishing device were studied to determine their influence on efficiency of magnetorheological finishing(MRF)and surface of MRF,as well as interaction between efficiency and surface.Based on theoretical and experimental research,the law of material removal was explored and a new process variable based material removal model(PVMR)was proposed.The experimental findings demonstrate that PVMR reveals the law of the material removal with introduction of three concepts and makes a material removal function z(y i)where the magnetorheological finishing process parameters are considered since they are easy to control and adjust.So the material function of this model is quadratic curve function which is readily suitable for stability and online control magnetorheological finishing.

Advanced nonlinear rheology magnetorheological finishing: A review

High-performance devices usually have curved surfaces, requiring high accuracy of shape and low surface roughness. It is a challenge to achieve high accuracies for form and position on a device with low surface roughness. However, due to the unique nonlinear rheology, magnetorheological fluids with hard abrasives are widely applied in ultra-precision surface finishing. Compared with conventional mechanical finishing, magnetorheological finishing displays obviously advantages, such as high precision shape of machined surface, low surface roughness and subsurface damage, and easy control for finishing processes. However, finishing performance depends on various factors, e.g. volume fraction and distribution of magnetic particles, types of hard abrasives and additives, strength of magnetic field, finishing forms. Therefore, a comprehensive review on related works is essential to understand the state-of-the-art of magnetorheological finishing and beneficial to inspire researchers to develop lower cost, higher machining accuracy and efficient approaches and setups, which demonstrates a significant guidance for development of high-performance parts in fields of aerospace, navigation and clinical medicine etc. This review starts from the rheological property of magnetorheological fluids, summarizing dynamically nonlinear rheological properties and stable finishing approaches. Then, the effect of components in magnetorheological fluids is discussed on finishing performance, consisting of magnetic particles, carrier fluid, additives and abrasives. Reasonable configuration of magnetorheological fluids, and different magnetorheological finishing methods are presented for variously curved surfaces. In addition, the current finishing forms and future directions are also addressed in this review.

Material removal model of magnetorheological finishing based on dense granular flow theory

Magnetorheological finishing(MRF)technology is widely used in the fabrication of high-precision optical elements.The material removal mechanism of MRF has not been fully understood because MRF technology involves the integration of electromagnetics,contact mechanics,and materials science.In this study,the rheological properties of the MR polishing fluid in oscillation model have been investigated.We propose that the shear-thinned MR polishing fluid over the polishing area should be considered a dense granular flow,based on which a new contact model of MRF over the polishing area has been constructed.Removal function and processing force test experiments were conducted under different working gaps.The normal pressure and effective friction equations over the polishing area were built based on the continuous medium and dense granular flow theories.Then,a novel MRF material removal model was established.A comparison of the results of the theoretical model with actual polishing results demonstrated the accuracy of the established model.The novel model proposed herein reveals the generation mechanism of shear force over a polished workpiece and realizes effective decoupling of the main processing parameters that influence the material removal of MRF.The results of this study will provide new and effective theoretical guidance for the process optimization and technology improvement of MRF.

Relationship between subsurface damage and surface roughness of ground optical materials

A theoretical model of relationship between subsurface damage and surface roughness was established to realize rapid and non-destructive measurement of subsurface damage of ground optical materials.Postulated condition of the model was that subsurface damage depth and peak-to-valley surface roughness are equal to depth of radial and lateral cracks in brittle surface induced by small-radius(radius≤200 μm)spherical indenter,respectively.And contribution of elastic stress field to the radial cracks propagation was also considered in the loading cycle.Subsurface damage depth of ground BK7 glasses was measured by magnetorheological finishing spot technique to validate theoretical ratio of subsurface damage to surface roughness.The results show that the ratio is directly proportional to load of abrasive grains and hardness of optical materials,while inversely proportional to granularity of abrasive grains and fracture toughness of optical materials.Moreover,the influence of the load and fracture toughness on the ratio is more significant than the granularity and hardness,respectively.The measured ratios of 80 grit and 120 grit fixed abrasive grinding of BK7 glasses are 5.8 and 5.4,respectively.