A numerical approach on the finishing efficiency of magnetorheological abrasive flow finishing (MRAFF) process was performed in the present study. MRAFF is basically a combination of abrasive flow maching (AFM) and magnetorheological finishing (MRF). This process relies on smart magnetorheological fluids whose rheological behaviour is controllable by means of external magnetic field. It was developed for super finishing of internal geometries of hard materials. Generally speaking, the viscosity of magnetorheological polishing fluid (MRPF) will become large with enhancement of the external magnetic field, Generally speaking, the viscosity of MRPF will be enhanced with the external magnetic field larger, and the effect of polishing is better. But if unlimited increase the viscosity of MRPF, may be to cause negative impact on the MRPF mobility, even scratched the workpiece. Therefore, in order to incorporate better in-process control of finishing action and to study the effects of various process parameters, numerical investigations into the mechanism of MRAFF process is necessary.
This research has established the analysis tool of MRAFF process. Simultaneously, the performance analysis to estimate the planar material removal obtained during MRAFF under the different magnetic field strength is also proposed. The predicted result showed that magnetic field strength significantly affects the viscosity of MRPF and material removal. When the external magnetic field is 0.25 Tesla, obtained finishing efficiency is the highest.