Novel Process Modeling of Magnetic-Field Assisted Finishing (MAF) with Rheological Properties

The performance of a magnetic-field-assisted finishing (MAF) process, an advanced surface is severely affected by the rheological properties MAF brush. yield stress and viscosity brush, comprising iron particles abrasives mixed in liquid carrier medium, change depending on brush’s constituents applied magnetic field, which turn affect material removal mechanism corresponding final roughness after MAF. A series experiments was conducted to delineate effect processing conditions experimental data were fitted into commonly used rheology models. Herschel–Bulkley (HB) model found be most suitable fit (lowest sum square errors (SSE)) for shear stress–shear rate obtained from tests calculate Processing parameters, such as flux density, weight ratio abrasives, abrasive (black ceramic this study) size, with p-values 0.031, 0.001 0.037, respectively, (each them lower than significance level 0.05), all statistically significant parameters that Yield increased density brush decreased size. new process model, rheology-integrated (RM), formulated using HB determine indentation depth individual workpiece during process. calculated enabled us predict (MRR) instantaneous roughness. predicted MRR RM better pre-existing contact mechanics (CMM) wear (WM) R2 0.91 compared 0.76 0.78 CMM WM. Finally, RM, under parametric variations, showed increases decreases rotational speed, initial increase, size decreases.