Title: Optimum selection of machining parameters in ball end magnetorheological finishing process

Authors: Mahendra Singh Niranjan; Sunil Jha

Addresses: Department of Mechanical Engineering, Delhi Technological University, New Delhi 110042, India ' Department of Mechanical Engineering, Indian Institute of Technology Delhi, Hauz Khas, New Delhi 110016, India

Abstract: Ball end magnetorheological finishing (BEMRF) tool has been used to finish mild steel work-piece surface using sintered magnetic abrasives based magnetorheological polishing (MRP) fluid. A comparative study has been done on mild steel surface with synthesised and unbounded magnetic abrasives based MRP fluid. Then percent reduction in surface roughness (%∆Ra) was calculated and compared. The response %∆Ra was found superior while finishing with synthesised MRP fluid. A detailed study with five levels and three factors central composite design of experiments (DOEs) was done to develop experimental plan. Response surface methodology (RSM) was adopted to predict the profile and %∆Ra. An effective second order response surface model was developed with significant factors and their interactions. Physical interpretation of effect of machining parameters on %∆Ra was analysed and obtained optimum values. Then experiment was conducted with optimum machining parameters and %∆Ra was calculated and compared with maximum %∆Ra obtained by regression model.

Keywords: sintering; magnetorheological polishing; MRP fluids; ball end MR finishing; BEMRF; DOE; design of experiments; RSM; response surface methodology; ANOVA; analysis of variance; optimisation; optimum selection; machining parameters; magnetorheological finishing; mild steel; magnetic abrasives; surface roughness; surface quality.

DOI: 10.1504/IJPTECH.2015.073826

International Journal of Precision Technology, 2015 Vol.5 No.3/4, pp.217 - 228

Received: 23 Apr 2015
Accepted: 18 Aug 2015

Published online: 23 Dec 2015 *

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