Rheological properties of abrasive magnetorheological fluids for immersed tumbling processes

Micro-milling tools face challenges related to wear and edge homogeneity, which are addressed through various post-processing methods including grinding with magnetorheological fluids (MRF). This paper explores the rheological properties of abrasive MRF, crucial for optimizing performance of recently investigated MRF immersed tumbling processes. A full factorial design of experiments investigates the effects of carbonyl iron particle (CIP) and abrasive particle (AP) volume fractions and AP diameter on yield point and dynamic viscosity. Using a specially developed rheometer test bench 27 different MRF compositions are evaluated. Results show that increasing CIP and AP volume fractions heighten shear stresses, while smaller AP diameters enhance shear stresses due to their solid-state chain embedding.