Theoretical analysis of forces in magnetorheological fluid based finishing process

Magnetorheological (MR) fluid based finishing process is a nano finishing process applicable to a large variety of materials. A theoretical model of forces (normal and tangential) acting on the workpiece is proposed to improve the in-depth understanding of the mechanism of material removal during MR fluid based finishing process. Two different theories are proposed to model the effect of abrasive particles concentration in the MR fluid. A normal and tangential squeeze force model is also proposed based on the theory of rolling process. A comparison of theoretical and experimental results is carried out to validate the proposed models which show their trends in good agreement.

► Models of normal and tangential forces acting on workpiece are proposed. ► A squeezing force model is proposed based on the theory of rolling process. ► Two theories are applied to study the effect of abrasive particles concentration. ► The models are validated with experiments and they are found in good agreement.