Design And Analysis Of Mr Finishing Tool For Nano Level Finishing On Non-ferromagnetic Workpiece Surface

The magnetorheological (MR) finishing process is a new and innovative technique used to polish materials with great precision. This work aims at designing and analyzing MRF using ANSYS Maxwell simulation software and STAT-EASE360 software. So the MR finishing process entails putting the MR fluid on a workpiece, which responds to change its properties when an applied magnetic field passes through it leading to polishing effect. In this model phase, there is the modeling of MR finishing tool in ANSYS Maxwell software and development of model in STAT-EASE360 software. STAT-EASE360 software was used to obtain different combination of bush height and number of turns, for which simulations were run. The maximum magnetic flux density was 1.941 Tesla at bush height of 5 mm and number of turns 2000. Besides that, we did important analysis for three different MR fluids concerning the magnetic flux density at bush height 5mm by use of three different MR fluids as well as number of turns 2000. The results from these simulations provide useful insight into the behavior of MRF during finishing process. The maximum flux density for MRF-122EG becomes equal to 1.740 Tesla that has been attained for bush height 5mm and number of turns equaling 2000. Lastly, in order to know how much each parameter influence on it we need analyze their impacts using analysis ANOVA allows for a statistical assessment of the significance of bush height and number of turns and its interaction with magnetic flux density, thereby aiding in process optimization and improvement. The predicted value of magnetic flux density was found to be 2.00994 Tesla, whereas the optimized value of magnetic flux density was found to be 2.010 Tesla at bush height 6.63 mm and number of turns 2133. The findings from the ANSYS Maxwell simulation and ANOVA analysis provide valuable information for enhancing the efficiency and effectiveness of the MRF process. The optimized design parameters can lead to improved surface quality, reduced processing time, and increased material removal rates, making the MRF process an attractive option for precision polishing in various industries.