Polishing characteristics of optical glass using PMMA-coated carbonyl-iron-based magnetorheological fluid

Soft magnetic carbonyl iron (CI) particles for magnetorheological (MR) polishing encounter corrosion problems as a result of their oxidation, leading to unpredictable polishing results. To overcome this issue, CI particles have been coated with either polymer or inorganic materials for improved MR polishing. In this study, CI particles were coated with poly(methyl methacrylate) to achieve improved MR polishing and anti-corrosion protection. In addition to an analysis of their rheological properties, a series of MR polishing experiments were performed to investigate the material removal rate and surface roughness for BK7 optical glass by changing experimental parameters, such as the wheel rotating speed and magnetic field intensity. A very fine surface roughness (Ra = 0.86 nm for PMMA coated CI Ra = 0.92 nm for pristine CI) was obtained at a wheel speed of 1256 mm s−1 and a magnetic field intensity of 15.92 kA m−1.