Aluminium is the most versatile engineering material for various industries, such as transport, machinery, metallurgy and printing. The aluminium cylindrical roller plays a significant role in the printing machine. In order to evenly distribute the pressure and for accurate tolerances roller needs to be perfect and uniformly finished. Owing to their ductility and lesser hardness, it is difficult to achieve uniform and fine finishing by conventional finishing methods. The rotary magnetorheological (MR) method is established to satisfy this requirement. The MR polishing fluid composition is initially analysed in order to obtain a fine finish. The central composite design was employed to optimize the finishing parameters. The batch gradient descent algorithm is used to validate the RSM optimization of process parameters. Batch gradient descent gives the mathematical model which validates the RSM mathematical model. The scan electron microscopy, reflectivity test and surface roughness profile check were carried out to track the surface texture and the cylindrical aluminium roller's ruggedness. The standard deviation test is performed to measure the uniformity of the finished surface and demonstrate that the uniformity of the finished surface which is increased. Geometric measurements are tested by the way of the surface waviness measurement. The results of earlier process parameters and with addition of reciprocation of work-part is compared and experimentation performed on 120 mm long and 25 mm diameter of the aluminium cylindrical roller with 30 mm length for each trial.

The surface quality of biomedical implants, such as shoulder joint caps, plays a critical role in their performance, longevity, and biocompatibility. Most biomedical shoulder joints fail to reach their optimal functionality when finished through conventional techniques like grinding and lapping due to their inability to achieve nanometer-grade smoothness, which results in greater wear and friction along with potential failure. The advanced magnetorheological finishing (MRF) approach provides enhanced surface quality through specific dimensional control material removal. This research evaluates how MRF treatment affects the surface roughness performance and microhardness properties and wear resistance behavior of cobalt–chromium alloy shoulder joint caps which have biocompatible qualities. The study implements a magnetorheological finishing system built with an electromagnetic tool to achieve the surface roughness improvements from 0.35 µm to 0.03 µm. The microhardness measurements show that MRF applications lead to a rise from HV 510 to HV 560 which boosts the wear protection of samples. After MRF finishing, the coefficient of friction demonstrates a decrease from 0.12 to 0.06 which proves improved tribological properties of these implants. The results show that MRF technology delivers superior benefits for biomedical use as it extends implant life span and decreases medical complications leading to better patient health outcomes. The purposeful evaluation of finishing techniques and their effects on implant functionality demonstrates MRF is an advanced technology for upcoming orthopedic implants while yielding high precision and enhanced durability and functional output.

The cylindrical copper rollers are an essential part of the printing process. The copper roller needs to be finely finished to ensure the even distribution of the colors. Fine and precise polishing of cylindrical copper rollers is challenging using conventional finishing procedures because of their ductility and low hardness. Therefore, the magnetorheological finishing process based on three revolving flat-tip tools has been used to meet this precise requirement. The optimized parameters were found as current 3.5A for the electromagnet, rotating speed of the workpiece 510 rpm, revolving speed of the tools 35 rpm, working gap 0.7 mm and feed rate 150 mm/min for maximum percentage reduction in the surface roughness of copper roller. After 4 h of finishing with the optimal parametric settings, the Ra, Rq, and Rz values were reduced to 0.08, 0.1, and 0.67 μ m from the initial values of 0.375, 0.527, and 1.96 μ m, respectively, across the copper roller surface. Surface roughness profiles, SEM, and mirror-image tests reveal the superiority of the magnetorheologically finished roller surface compared to the unfinished one.

Background: The consistency of the magnetorheological process insisted that the Inconel® 718 material should be furnished. This process involves every material from the categories of soft and hard materials. Aim: In this study, a cylindrical ferromagnetic work-part was finished using the magnetorheological finishing method. Objective: The strength of the magnetic flux controls the density and forces in processes that are assisted by magnetic fields. The mechanism was studied parametrically in this research work using response surface methodology Methods: Optimal process parameters were determined using response surface methodology to accurately execute the finishing procedure. Each parameter's percentage consumption to the process's finishing output was also estimated. The finishing of an industrial extrusion punch was carried out using the optimum parameters obtained from the parametric analysis. Results: The RSM optimisation of process parameters is validated using the batch gradient descent (BGD) algorithm which is the best fit and innovation algorithm for these types of optimization solutions. The mathematical model that BGD provides confirms the RSM mathematical model. Conclusion: The optimized parameters are useful in controlling the capability of the MR finishing process in various industrial applications.

This study investigates the effectiveness of a newly developed magnetorheological fluid (MRF) finishing process in improving the surface quality of P20 steel mold punches, which are crucial for producing smooth plastic components in casting. Surface quality of molds and punches improves product quality, enhances precision, reduces wear, optimizes material flow, minimizes defects, and extends the lifespan of the die and punch. The MRF finishing process utilizes abrasive particles suspended in MR fluid to achieve a fine surface finish. The research aims to evaluate the feasibility of the new developed MRF process for finishing hard materials and examines the influence of a new finishing parameter percentage of abrasive particle concentration along with four other key finishing parameters using the Taguchi method. After 45 min of finishing, a significant reduction in surface roughness is observed, decreasing from 0.247 µm to 0.065 µm. Among the parameters studied, abrasive particle concentration is identified as the most influential factor in achieving this reduction. To assess the process's effectiveness, the initial surface and the MR-finished surface are compared using a Taylor Hobson Surftest-25 roughness tester, scanning electron microscopy, and mirror image tests. The results confirm that the newly developed MRF process significantly enhances surface quality, reducing roughness to the nano level and refining the microscopic surface of the mold punch.