Titanium alloy with high corrosion resistance, high strength-to-density ratio, and excellent biocompatibility has a wide range of applications in the field of biomedical implants. Polishing experiments of titanium alloy with a small size and complex shapes were investigated using an ultrasonic assisted magnetorheological finishing (UMRF) device excited by a three-pole magnetic field generator. The models of the normal force and the shear force were first proposed based on the Preston equation to analyze the mechanism of material removal in the UMRF process. Subsequently, the single-factor experiments using titanium alloy nuts (M3) and the MR polishing fluid with silicon carbide abrasives were carried out. Furthermore, to improve the surface roughness and the change rate of surface roughness of nuts, orthogonal tests with a standard L9(34) orthogonal array were designed and performed based on the optimized process parameters obtained from the single-factor experiment. The results indicated the effect on surface roughness and change rate of surface roughness as applied current > roller speed > ultrasonic amplitude > spindle speed and applied current > roller speed > spindle speed > ultrasonic amplitude, respectively. Moreover, the surface roughness was improved from an initial 1.247 µm to a final 0.104 µm after the polishing for 80 min under these optimal process parameters.
Transient behavior of a magnetorheological brake excited by step currents under compression-shear mode has been experimentally studied. The results show that the amplitude of the applied current had little effect on the rising time of transient torque, while the rising time was significantly affected by the rotational speed, the compressive speed and the compressive strain position. The falling time of transient torque was independent of the amplitude of the applied current, the compressive speed and the compressive strain position, and it was affected by the rotational speed. The falling time of the transient torque was much shorter than the rising time by a step current. The transient process of MR brake applied as a step current was different from a stable process pre-applied at constant current in different particle chain structure forming processes. In addition, the compressive processes applied in one step current and randomly on/off current were compared and experimentally verified: the particle chains in two processes both experienced the same evolutionary of transient torque. The results achieved in this study should be properly considered in the design and control of magnetorheological brake under compression-shear mode.
