Synergistic Effect of Rotating Magnetic Field and Ultrasonic Vibrations in Magnetorheological Abrasive Flow Finishing

Document Type : Research Article

Authors

1 Department of Mechanical Engineering, Meybod University, Meybod, Iran

2 Mechanical Engineering Department, Amirkabir University of Technology, Tehran, Iran

Abstract

In this study, a rotating magnetic field and ultrasonic vibrations are employed as an effective solution to address the challenges of the magnetorheological abrasive flow finishing (MRAFF) process. To achieve this goal, an industrial-scale MRAFF setup was first designed and fabricated. After preparing the magnetorheological polishing (MRP) fluid, a rotating magnetic field was applied, and ultrasonic vibrations were subsequently introduced perpendicular to the fluid flow direction onto the workpiece. To evaluate the performance of the proposed method, the influence of processing time on three key indicators—surface roughness ratio, finishing rate, and material removal rate—was investigated in 2024 aluminum alloy tubes. The results revealed that within the first 10 minutes of processing, not only did the surface roughness ratio decrease, but the finishing rate and material removal rate also increased. However, prolonging the process led to a resurgence in surface roughness due to the detrimental effects of abrasive particles. Microscopic images not only confirmed these findings but also demonstrated that under optimal conditions, the proposed method produced a uniform surface and reduced the internal tube roughness by up to 98%. Consequently, this method presents a promising and efficient solution for finishing and deburring internal surfaces, particularly in long tubular components.

 

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Amirkabir Journal of Mechanical Engineering
Volume 57, Issue 4
July 2025
Pages 453-472

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