Experimental study on magnetorheological polishing fluids composition in reciprocating magnetorheological polishing

As the main factor of magnetorheological polishing (MRP), the magnetorheological polishing fluids (MRP fluids) directly affect the machining results of the workpiece surface. In this study, the preparation and performance test of MRP fluids are carried out. It is to evaluate the polishing effects of the workpiece by experimental design of the prepared MRP fluids composition, that is, the concentration of carbonyl iron particles (CIPs), the concentration of cerium oxide (CeO2), and the size of cerium oxide (CeO2) using reciprocating polishing method and establish regression equation models. Further, the optimum MRP fluids composition parameters are obtained by the optimization of regression models of the ΔRa and MRR, and the correctness of optimization results of regression models is validated by experimental verification. The results show that the ΔRa and MRR of the workpiece are affected by the MRP fluids composition parameters. The optimum MRP fluids composition parameters are found at 40 vol.% concentration of CIPs, 5 vol.% concentration of CeO2, and 7000 mesh size of CeO2. The experimental results of the ΔRa and MRR are deviated by 4.95% and 4.17% from the response results respectively by experimental verification.