Process parameter effects on material removal in magnetorheological finishing of borosilicate glass.

We investigate the effects of processing parameters on material removal for borosilicate glass. Data are collected on a magnetorheological finishing (MRF) spot taking machine (STM) with a standard aqueous magnetorheological (MR) fluid. Normal and shear forces are measured simultaneously, in situ, with a dynamic dual load cell. Shear stress is found to be independent of nanodiamond concentration, penetration depth, magnetic field strength, and the relative velocity between the part and the rotating MR fluid ribbon. Shear stress, determined primarily by the material mechanical properties, dominates removal in MRF. The addition of nanodiamond abrasives greatly enhances the material removal efficiency, with the removal rate saturating at a high abrasive concentration. The volumetric removal rate (VRR) increases with penetration depth but is insensitive to magnetic field strength. The VRR is strongly correlated with the relative velocity between the ribbon and the part, as expected by the Preston equation. A modified removal rate model for MRF offers a better estimation of MRF removal capability by including nanodiamond concentration and penetration depth.