Executive Summary : | Polymer-based 3D printed are highly demanded materials in a variety of industrial sectors due to their characteristics such as lightweight, corrosion resistance, impact resistance, and excellent formability. However, due to characteristics like poor wear resistance and low hardness, polymers must have their surfaces finished at a precise level in a controlled environment. Additionally, due to the benefits of simpler processing and design freedom, additive manufacturing is used to produce the majority of polymer components. Due to the nature of the powder-based layer-by-layer deposition process, the surface quality of the final components produced by additive manufacturing is found to be subpar. Poor mechanical and manufacturing properties are a drawback that has delayed the use of polymer-based components in many industries. Additionally, the majority of surface finishing techniques are either unable to produce finishes that meet specifications or are unable to control finishing forces, both of which result in surface subpar. However, the magnetorheological finishing (MR) process provides a clean and damage-free surface that results from the extremely low normal forces acting on an abrasive. The application of the present research work can be found in the automotive, aerospace, optical, and medical industries on a large scale. Since the use of the 3D printed polymer parts is very precise and they may inherently surface irregularities that lead to wear and friction, therefore proper surface finishing is required. Sometimes in severe cases, friction can cause overheating, which is likely to have adverse effects and also cause wear. Similarly, polymers such as UHMWPE and polycarbonate are widely used in the medical sector. Hip joint implants, knee joint implants, and dentistry are a few areas where a precise polymer surface finish is required. The present proposed work can improve the functional life of 3D printed polymer implants, etc. by lowering wear and friction through a reduction in the roughness value. Hence, in the present work, the advantage of the magnetorheological finishing process is to explore further the fine finishing of various 3D printed polymer industrial components having free-form surfaces. Therefore, the different magnetically controllable finishing tools, as well as workpiece fixtures, are designed and fabricated. Further, to validate the efficacy of various designed MR finishing tools, the experimentations are to be performed over the different free-form shapes of 3D printed polymer components. The best process parameters for finishing the various free-form shapes and types of 3D printed polymer workpieces used in sectors like the medical, automotive, marine, etc. are then to be predicted. Finally, the desired performance of the 3D printed free-form finished polymer workpiece surfaces will be investigated using surface roughness profiles, surface characteristics, and mechanical properties. |