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Design and fabrication of a novel magnetorheological finishing process for small concave surfaces using small ball-end permanent-magnet polishing head

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Abstract

In order to overcome the defects of conventional magnetorheological finishing (MRF) processes that are unable to finish small curvature radius concave surfaces of diameter within 10 mm, a novel precision MRF process using small ball-end permanent-magnet polishing head with a diameter of 4 mm is proposed in this paper. And experimental setup of a four-axis linkage MRF machine tool is fabricated. Magnetostatic simulation of the distribution of magnetic flux density indicates that the magnetic field uniformity of produced polishing head is 93.3 %. Magnetizing force analysis is done to analyze the formation of magnetorheological fluid in finishing region. In addition, the suitable range of C-axis angular position for finishing is generated to be 60°~70°. Finishing experiments on both nonmetallic and metallic specimens with different surface shapes have been conducted. The ability of the developed method of finishing process to improve surface characteristics of a workpiece is demonstrated to reach the surface roughness of finished surfaces below Ra 6 nm. It confirms that the present MRF process is capable of improving surface quality and performing the nanofinishing on small curvature radius concave surfaces.

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Authors and Affiliations

  1. Center for Precision Engineering, Harbin Institute of Technology, P.O. Box 413, Harbin, Heilongjiang, 150001, China

    Mingjun Chen, Henan Liu & Yinrui Su

  2. China Electronics Technology Group Corporation No.26 Research Institute, Chongqing, 400060, China

    Bo Yu & Zhen Fang

Authors
  1. Mingjun Chen
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  2. Henan Liu
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  3. Yinrui Su
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  4. Bo Yu
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  5. Zhen Fang
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Correspondence to Mingjun Chen.

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Chen, M., Liu, H., Su, Y. et al. Design and fabrication of a novel magnetorheological finishing process for small concave surfaces using small ball-end permanent-magnet polishing head. Int J Adv Manuf Technol 83, 823–834 (2016). https://doi.org/10.1007/s00170-015-7573-5

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  • DOI: https://doi.org/10.1007/s00170-015-7573-5

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