Abstract: To realize the prediction of surface roughness of laser-assisted magnetorheological finishing with spherical tool, the magnetic field intensity of permanent magnet spherical polishing head is analyzed by using finite element simulation.Based on fluid-solid coupling heat transfer theory, the effects of laser temperature field on the magnetic buoyancy and hydrodynamic pressure are analyzed, and the mathematical equations of normal pressure are established, furthermore, the relationship between normal pressure and intruded depth of abrasive is gained.Combining with the kinematic analysis of abrasive, a reconstruction algorithm of machined surface topography is proposed, and then the predictive model of machined surface roughness is established and certified by experiments, moreover, the effect of procession parameters on machined surface roughness is revealed.The results indicate that laser-assisted magnetorheological finishing can effectively reduce surface roughness, and the relationship between laser power and surface roughness is not monotonically increasing or decreasing as well as spindle speed and polishing gap to surface roughness.Within the value range of parameters in experiments, there is an optimal value for each parameter.Comparing experimental results with predictive results, there is a good agreement, and the maximum prediction error is 16.3%.

Key words: laser-assisted, magnetorheological polishing, surface roughness, predictive model