Optimization of the Removal Function of Dual-Rotation Magnetorheological Finishing

Magnetorheological finishing (MRF) is an advanced polishing technique capable of rapidly converging to the required surface figure. In this article, dual-rotation MRF tool is used to generate centrosymmetric removal function that can be W-shaped or Gaussian-shaped. Using W-shaped removal function and Gaussian-shaped removal function respectively, this article compares the convergence of surface error by simulating the finishing process through iterative calculations. Furthermore, it compares mid-spatial-frequency surface error caused by the two removal functions, through 2D FFT and PSD estimation in the frequency domain. From simulation, this article proves that Gaussian-shaped removal function is more advantageous than W-shaped removal function. To solve the problem that the removal function obtained in dual-rotation MRF is W-shaped, this paper presents the method of adjusting the distance between the axes of self-rotation and co-rotation to secure Gaussian-shaped removal function. Finally, experiments have been conducted to demonstrate validity of the method.