On the effect of relative size of magnetic particles and abrasive particles in MR fluid-based finishing process

Magnetorheological fluid-based finishing (MRFF) process is widely used for fabrication of optical material such as glasses, lenses, mirrors, etc. Performance of the process is significantly affected by the properties (size, concentration, hardness, etc.) of the constituents of MR fluid. MR fluids have been prepared by varying three abrasive particles mean sizes (4 µm, 6 µm and 9 µm) with carbonyl iron particles (CIPs) having average particles size of 6 µm. Yield stress of MR fluids is measured using a rheometer. The composition of the fluid has CIPs of 25%, abrasive 10% (by volume) and rest of the base medium (liquid). The yield stress was evaluated at magnetic flux density of 0.33 Tesla. It is observed that MR fluid having the same particle size of CIPs and abrasive particles exhibits higher yield stress as compared to other combinations. The lowest yield stress is observed in case of 9 µm abrasive particles size. A set of finishing experiments is carried out to understand the effect of relative size of magnetic particles and abrasive particles on surface roughness values.