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Differential finishing of freeform surfaces (knee joint) using R-MRAFF process and negative replica of workpiece as a fixture

ABSTRACT It is difficult and challenging to achieve uniform nanoscale surface finish in the contact zone, particularly on freeform (or sculptured) surfaces having different curvatures at different locations. Femoral (or, Knee joint component) is one of such biomedical freeform component which has complex profile along its curvature. Surface conditions of a femoral decide the life of the implant and they play a crucial role in its functionality. The variation in surface roughness of the femoral should be minimum in the contact zone. For this purpose, a special tooling is being proposed for rotational magnetorheological abrasive flow finishing (R-MRAFF) process. A negative replica of the workpiece (knee joint) as a tool (or a fixture) is used so that the medium flow velocity in the fluid flow channel is almost constant (or minimum possible variations) along the medium flow direction. It is able to do differential finishing also along the curvature. In addition, pulsating magnetic field has been used to generate vibrations in the medium in the finishing zone so that the possibility of fresh abrasive particles interacting with the surface of femoral is high. The surface finish has been achieved ranging from 26 nm to 62 nm using the proposed finishing technique and negative replica of the workpiece (femoral) as a fixture.