Effect of optimum process parameters in rotational-magnetorheological poppet valve polishing.

Poppet valves are commonly used as relief valves, pressure regulators, selectors, and inlet and exhaust valves in automobile internal combustion (IC) engines. Nanofinishing of ridge profiles of the poppet valve is a challenging task due to its narrowness. This article presents the precise finishing of narrow ridge profiles of poppet valves at optimum process parameters in the rotational-magnetorheological fluid-based finishing (R-MRFF) process using a novel magnet fixture. Statistical analysis is used to determine the impact of each process parameter. Further, simulation of finishing forces in the R-MRFF process is performed using software that applies the finite element technique. Investigation of finishing forces assists in controlling the process precisely. An analytical model is formulated for calculating the number of abrasive particles acting on nickel–aluminum–bronze alloy poppet profiles to anticipate final material dislodgement. The significant process parameters for surface roughness are abrasive volume concentration, poppet rpm, poppet vertical feed rate, and carbonyl iron particle (CIP) volume concentration. The minimum obtained surface roughness (Ra) at poppet valve profiles is 23.5 nm. The final finished poppet valve may have a longer service life and improved wear and corrosion resistance at maximum temperature and pressure. [ABSTRACT FROM AUTHOR]