Numerical Analysis and Optimization of Magnetic Flux Density in the Polishing Process with Magnetorheological Fluid

In the finishing process of optical parts, achieving minimum surface roughness and high profile precision are of great importance. Due to brittle nature and high hardness of these materials, the finishing process will induce surface and subsurface damages which can be removed by a polishing process. One of these processes is magnetorheological finishing. In this process, the rheological property of magnetorheological fluid changes by the inducted magnetic field at material removal region. In the present study, finite element analysis has been carried out to optimize the magnetic flux density in the material removal region. In order to analyze the magnetic field, the effective parameters on the amount of magnetic flux density are identified and their influence is investigated. Taguchi design of experiment method was used to reduce the number of numerical runs. By considering the finite element results and fabrication restrictions, the genetic algorithm is used for the optimization of parameters. The magnetorheological system was made with the optimized parameters and the amount of magnetic flux density was measured. The results show that the variations of poles angle, poles and the wheel wall thickness have remarkable influence on magnetic flux density in the material removal region.