Machining method for controlling the behaviours of Bingham fluids in cluster magnetorheological polishing pads

Abstract

Cluster magnetorheological finishing is a novel machining method for attaining super-smooth and even surfaces. The aim of the research is to strengthen the role of cluster magnetorheological polishing pads and improve the material removal rate (MRR) while attaining smooth and undamaged surfaces. To this end, a novel polishing disk with three-dimensional (3D) microstructures was formed by machining an array of holes on the surface of a polishing disk. The influences of the type of abrasives, geometric parameters of the holes, and polishing time on the roughness and MRR of the machined surface were explored. The test result showed that a polishing disk with multiple holes contributes to a higher MRR and a lower surface roughness relative to a smooth polishing disk, significantly improving the polishing effect; the diameter and distribution of multiple holes on the surface of the polishing disk exhibit a significant effect on the polishing process. The polishing effect with silica sols is most remarkably improved. The solid-state chemical reaction between sapphire and silica sols promotes material removal; relative to a smooth polishing disk, the MRR is increased by 107% and the surface roughness is decreased by 11%. The surface roughness is reduced from Ra 5.14 nm to Ra 0.24 nm by utilising the optimised technological parameters. Under the synergistic action of mechanical removal enhancement of polishing disks with multiple holes and chemical removal of silica sol sapphire can obtain super smooth undamaged surfaces efficiently.

Magnetorheological Polishing Based on Honing Vertical Mechanism for Inner Surface of Titanium Alloy Pipes

“…Barman and Das [9] proposed an MR nanofinishing process to generate different surface morphologies on the bio-titanium alloy by changing the fluid composition, and showed that a bio-titanium polished surface using MR fluid with Type-I polishing medium is hydrophilic in nature, and it is better suited for semi-permanent type of implants and also for implants which engaged with the relative motion of the human body. Yan et al [10] explored a cluster MR finishing process by machining an array of micro-holes on the surface of the polishing disk, and the test result showed that the polishing disk with multiple holes contributed to a higher material removal rate and a lower surface roughness relative to a smooth polishing disk.…”

A Novel Magnetorheological Fluid with High-Temperature Resistance

“…Currently, MR fluid, the most widely studied and applied MR material, is commonly used in active vibration control [ 3 , 4 , 5 , 6 , 7 ], transmission [ 8 , 9 ], braking [ 10 , 11 ], polishing [ 12 , 13 ], sealing [ 14 , 15 ], suspensions [ 16 ], haptic modules [ 17 , 18 ], and so on [ 19 , 20 , 21 , 22 , 23 ]. However, problems with temperature rises are inevitable in most MR devices.…”

Influence of Magnetic Field on Sound Transmission Loss of the Unit Filled with Magnetorheological Fluid

“…Moreover, the transition response between their fluid- and solid-like states is quick, and this transition process is reversible [ 3 , 4 ]. Given these advantages, MRFs have been applied in many engineering fields, such as polishing [ 5 ], sealing [ 6 ], braking [ 7 ], vibration control [ 8 , 9 ], etc. In addition to MRF dampers, the vibration-suppressing performance of MRF-based structures under an external magnetic field has been extensively investigated.…”