Improvement in Surface Characteristics of SS316L Tiny Gear Profiles by Magnetorheological-Polishing Fluid Using Flow Restrictor

Nano-finishing of small-scale gears is difficult because their geometric complexity is really challenging. The high-speed application causes noise or vibration between the meshing teeth. The traditional method for finishing of tiny gears produces a surface error on its profiles. Very few finishing processes can be applied to SS316L tiny gears due to the narrow spacing between their teeth. In the current study, the stainless-steel tiny gear teeth profiles are polished using a novel flow restrictor by the magnetorheological-polishing fluid-based finishing process. The minimum ultrafine surface roughness R-a of 23.9 nm at tiny gear teeth profiles is obtained. All surface defects like burrs, dents, scratches and pits are also completely removed. The finishing results are compared with and without using a flow restrictor. A theoretical analysis of the magnetic force responsible for finishing is also done to recognize the process accurately.

Automated summary

Nano-finishing of small-scale gears is challenging due to their geometric complexity and narrow spacing between teeth. A novel flow restrictor and magnetorheological-polishing fluid are utilized to polish stainless-steel tiny gear teeth profiles, achieving a minimum surface roughness of 23.9 nm and removing all surface defects effectively. Theoretical analysis of magnetic force responsible for finishing process is also conducted to accurately understand the process.