Simulation and experimental investigation of finishing forces in magnetic field assisted finishing process

Finishing forces in magnetic field assisted finishing process are normal force responsible for indentation and tangential force responsible for removal of indented materials. Analysis of finishing forces helps to understand the process mechanism and to control the process precisely. Simulation of finishing forces in magnetic field assisted finishing process is conducted using two finite element method based software packages. The experimental study confirms the simulation results as the difference between the obtained results from both the study is very small. A model is simulated for material removal using magnetorheological fluid having diamond abrasive particles on Ti alloy workpiece surface to predict material dislodgement during finishing. The significance of each process parameters is found out with the help of statistical analysis. The significant process parameters for normal force are abrasive volume concentration, working gap and carbonyl iron particle (CIP) volume concentration and for tangential force are tool rpm, working gap, and CIP volume concentration. It is perceived that the normal force rises with a surge in CIP concentration and reduction in abrasive concentration in MR fluid, working gap and tool rpm. The magnitude of tangential force rises with increased tool rpm, CIP concentration, abrasive concentration and decreased working gap.