Multi-stage process optimization and efficiency improvement for magnetorheological polishing of glass-ceramics

The magnetorheological fluid composition (MFC) and process parameters significantly affect the efficiency and quality of magnetorheological polished (MRP) glass-ceramics. This study employed a single-factor experiment to determine the optimal MFC. Nanoindentation experiments were conducted to analyze material removal characteristics induced by chemical action. Response surface method (RSM) was utilized to optimize the process parameters. Finally, the optimized parameters were applied to the multi-stage MRP process. The results show that the optimal MFC as follows: polishing time is 60 min, abrasive is cerium oxide, particle size is 1.5 μm, and pH = 9. Chemical action reduces the surface hardness, thereby increasing the material removal rate (MRR). The prediction model constructed by RSM showed high reliability with an R² of 0.9745. The polishing process was carried out for 20 min using the optimal MRR parameters (workpiece speed 800 r/min, disc speed 90 r/min, working gap 2 mm, yaw speed 120 mm/min), followed by 24 min using the optimal surface roughness (Sa) parameters (workpiece speed 400 r/min, disc speed 90 r/min, working gap 2.4 mm, yaw speed 80 mm/min). This resulted in a MRR of 0.716 μm/min and Sa of 2.423 nm. Multi-stage polishing improved efficiency by 26.7 % and reduced costs compared to single-stage polishing. It provides a new technical support for the development of MRP glass-ceramics.