Improve Surface Quality Research Articles

Preparation Technuques for Perovskite Single Crystal Films: From Nucleation to Growth.

Thickness-controllable perovskite single crystal films exhibit tremendous potential for various optoelectronic applications due to their capacity to leverage the relationship between diffusion length and absorption depth. However, the fabrication processes have suffered from difficulties in large-area production and poor quality with abundant surface defects. While post-treatments, such as passivation and polishing, can provide partial improvement in surface quality, the fundamental solution lies in the direct growth of high-quality single crystal films. In this work, we firstly summarize the basic principles of nucleation and growth phenomenon of crystalline materials. Advanced growth methods of perovskite single crystal films, including solution-based, vapor phase epitaxial growth, and top-down method, are discussed, highlighting their respective advantages and limitations. Finally, we also present future directions and the challenges that lie ahead in perovskite single crystal films.

A two-step hydrothermal method for micro/nanotextured titanium implants and their integration outcomes in goat mandible.

A crucial aspect of contemporary dental implant research is modifying implant microdesign to achieve early and robust osseointegration. This study describes a new facile subtraction approach for microdesign modification of titanium implants using akali-hydrothermal followed by ion-exchange reaction (AHIE) in a salt solution, and compares osseointegration performance to machined titanium alloy (negative control) implants. The morphology, wettability, and roughness of the implant surfaces were evaluated. Twenty-four cylinders (two types/side) were inserted into the right and left mandibles of six Bengal goats in opposite order. The implant-bone interface was examined at 8 and 16 weeks following implantation using radiography, micro-computed tomography, histology, and scanning electron microscopy. After AHIE treatment, average surface roughness increased marginally (p > 0.05) due to predominantly micron-scale with random nano-scale alterations, whereas wettability improved substantially (p < 0.05). In addition to micro/nano-scale defects, the AHIE treatment produced few honeycomb-like surface patterns. The AHIE implants demonstrated early and direct bone to implant body contact, and achieved stronger bone fixation in vivo than machined implants. Based on laboratory and in vivo data, we conclude that AHIE processing of titanium implants may be a promising technique for improving surface quality while assuring secure and effective osseointegration for dental implant.

The Behaviour of carbon quantum dots and cryogenic cooling in turning of super duplex F 53 steel

The objective of this research is to examine how various cooling and lubrication techniques affect the machinability of Duplex F53 steel when turning it, with particular attention to residual stress, surface roughness, chip morphology, tool wear, machining temperature, and crystallographic structures. According to the microstructure analysis, the presence of additional austenite grains at high temperatures during dry machining results in an increase in hardness. On the other hand, cooling techniques including liquid nitrogen (LN2), carbon Quantum dots with SQL (CD), and oil with small quantity lubrication (OSQL) produce larger ferrite grains, which lower hardness. According to residual stress analysis, the high temperatures during dry cutting result in increased strains, which are successfully mitigated by lubrication. The two-phase microstructure has a crucial influence in mechanical characteristics, as demonstrated by X-ray diffraction (XRD) studies, wherein finer grains improve surface polish but demand more energy. Measuring surface roughness (Ra) reveals that adhesion wears during dry machining raises Ra, while OSQL and LN2 cooling lower Ra and improve surface quality. Tool performance is negatively impacted by high machining temperatures. Cutting temperatures and friction are greatly reduced by LN2 cooling. Dry machining increases tool wear because of the high temperatures and absence of lubrication; OSQL and CD lower wear rates, while LN2 offers the best protection for tools. Thinner, better-separated chips are produced by effective lubrication in OSQL and LN2, while thicker, more deformed chips are produced by dry machining, according to chip morphology and thickness analyses. The study leads to the conclusion that super duplex steel's surface quality, tool life, and machinability can all be significantly enhanced by carbon quantum dots and cryogenic cooling.

Assessment of cutting force coefficient identification methods and force models for variable pitch and helix bull-nose tools

The mechanistic approach is commonly implemented to predict and optimise the cutting forces in milling processes to prevent tool breakages, reduce tool wear, reduce form error, and improve surface quality. To implement this method, the cutting force coefficients (CFCs), that characterise the mechanics of the process, must be calculated. This study compares the accuracy of the predicted cutting forces for variable pitch and helix bull-nose milling tools using a rapid testing (RT) optimisation-based mechanistic CFC identification method that only requires a single angular cut with increasing radial engagement to the traditional mechanistic approach that requires several straight cuts. Along with developing a hybrid technique that combines variation in feed rate and radial engagement. The traditional radial, tangential, and axial (RTA) force model is also compared with the frictional and normal rake face (UV) force model that is independent of the local tool rake and inclination angles which is a necessary for bull nose tools. The RT and the developed hybrid CFC identification method with the UV force model predicted the average Fx, Fy and Fz cutting forces to within 7.1 %, 4.3 %, and 3.8 % error, respectively. These methods were slightly less accurate than the traditional method, however they have significant industrial benefits because they have can be used to identify CFCs with either a single cut, or from any tool-path with chip-load variation, respectively. The RTA force model predicted the average cutting forces similarly to the UV force model, however, the UV force model had lower errors using the rapid RT testing method at the extreme corners of the experimental design space.

A Five-Axis Toolpath Corner-Smoothing Method Based on the Space of Master–Slave Movement

The smoothing of linear toolpaths plays is critical in improving machining quality and efficiency in five-axis CNC machining. Existing corner-smoothing methods often overlook the impact of spline curvature fluctuations, which may lead to acceleration variations, hindering surface quality improvements. The paper presents a five-axis toolpath corner-smoothing method based on the space of master–slave movement (SMM), aiming to minimize curvature fluctuations in five-axis machining and improve surface quality. The concept of movement space in master–slave cooperative motion is introduced, where the tool tip position and tool orientation are decoupled into a main motion trajectory and two master–slave movement space trajectories. By deriving the curvature monotony conditions of a dual Bézier spline, a G2-continuous tool tip corner-smoothing curve with minimal curvature fluctuations is constructed in real-time. Subsequently, using the SMM and the asymmetric dual Bézier spline, a high-order continuous synchronization relationship between the tool tip position and tool orientation is established. Simulation tests and machining experiments show that with our smoothing algorithm, maximum acceleration values for each axis were reduced by 21.05%, while jerk was lowered by 22.31%. These results indicate that trajectory smoothing significantly reduces mechanical vibrations and improves surface quality.

Experimental Investigation of the Micro-Milling of Additively Manufactured Titanium Alloys: Selective Laser Melting and Wrought Ti6Al4V

In recent years, additive manufacturing (AM) has gained popularity in the aerospace, automobile, and medical industries due to its ability to produce complex profiles with minimal tolerances. Micro-milling is recommended for machining AM-based parts to improve surface quality and form accuracy. Therefore, the machinability of a titanium alloy (Ti6Al4V) manufactured using selective laser melting (SLM) is explored and compared to that of wrought Ti6Al4V in micro-milling. The experimental results reveal the surface topology, chip morphology, burr formation, and tool wear characteristics of both samples. The micro-milling of AM-based Ti6Al4V generates a surface roughness of 19.2 nm, which is 13.9% lower than that of wrought workpieces, and this component exhibits less tool wear. SLM-based Ti6Al4V produces continuous chips, while wrought Ti6Al4V yields relatively short chips. Additionally, SLM-fabricated Ti6Al4V exhibits smaller burrs after micro-milling than wrought Ti6Al4V. Despite the higher hardness of SLM-based Ti6Al4V, it demonstrates better machinability than wrought Ti6Al4V, resulting in better surface quality with lower tool wear levels and shorter burr heights. This study provides valuable insights into future research on postprocessing AM-based titanium parts, especially using micro-milling.

Influence of the Cooling Temperature on the Surface Quality in Integrated Additive and Subtractive Manufacturing of Aluminum Alloy.

The surface quality of parts processed by laser additive manufacturing, especially laser-based directed energy deposition (LDED), makes it difficult to meet actual use requirements. In addition, defects generated during the long-term additive manufacturing process need to be removed in time. Therefore, laser additive and subtractive manufacturing is of great significance for additive manufacturing. The main difference between laser additive-subtractive manufacturing and pure subtraction is that a cooling temperature is required due to the laser process. Therefore, this work studies the temperature variation regularity during LDED and the milling processes, as well as the surface roughness, cross-sectional microstructure, and tool wear under different cooling temperatures for milling. The results show that there is a "turning point temperature" in LDED, and the value of the turning point temperature gradually increases with heat accumulation, which affects the initial temperature of the subtractive manufacturing. When subtracting, a high initial temperature improves surface quality and reduces tool wear, but an excessively high temperature will cause the aluminum alloy to adhere to the tool. Then, the smear metal is difficult to effectively remove, deteriorates the milling quality, and aggravates tool wear. It is found that the higher the cooling temperature generated, the wider the thermally insulated shear band. The insulated shear band may affect the quality of the additive and subtractive manufacturing. Finally, it is determined that the milling temperature of aluminum alloy in this work condition is about 100 °C.

Stress-relief annealing friendly Fe-based metallic glass-reinforced Al-Si-Mg-Zr alloy fabricated by laser powder bed fusion

ABSTRACT To enhance the thermal stability of L-PBF Al-Si-Mg alloy, Fe-based metallic glass powder was mixed with Al-Si-Mg-Zr powder to fabricate a novel alloy via L-PBF. The study systematically investigated the effects of process parameters on processability and the impact of stress-relief annealing (300 ∘ C–2h) on the microstructure and mechanical properties. Results showed that metallic glass addition improved surface quality. Plastic deformation was analysed using finite element and molecular dynamics methods. The as-built alloy had a cellular substructure with Al 3 Zr, Si, AlFeMgSi, and AlFeSi phases. Si nanoparticles and stacking faults were observed in α-Al cells. The as-built samples had yield strength (YS) of 249±4 MPa, ultimate tensile strength (UTS) of 434±6 MPa, and 6.3±0.3% elongation. Post-annealing, the alloy retained high strength and plasticity with YS of 255±3 MPa, UTS of 449±15 MPa, and 7.2±0.3% elongation, outperforming similar L-PBF Al-Si and Al-Si-Mg alloys.

Study on micro-grinding mechanism and surface quality of hardened 20 vol% SiCp/Al composites

Particle-reinforced aluminum-based silicon carbide composites (SiCp/Al) are widely used in aerospace, rail transit, and other fields due to their excellent comprehensive properties. However, the incorporation of high-brittle SiC particles poses challenges in the high-performance processing of SiCp/Al composites. This study focuses on hardened 20 vol% SiCp/Al composites, establishing two-dimensional finite element cutting models for single SiC particles. Micro-grinding experiments are conducted under various processing parameters. The influence law of surface defects on individual SiC particles relative to tool position and single factor machining parameters was analyzed, revealing the micro-grinding mechanisms affecting surface and subsurface quality. The results show that the interaction among particle damage mechanisms, crack propagation directions, and the restraining effects of the Al matrix leads to diverse types of defects at different cutting positions. Both simulation and experimental observations reveal surface defects such as pits, gullies, and burrs, while subsurface damage primarily results from crack invasion, cavity interstices, and pits due to particle breakage. The experiment achieved a minimum roughness of 0.057 μm. Taking into account the thermal softening of the material and the micro-behavior of the tool-chip interface, optimal conditions for improved surface quality involve a grinding depth of 0.03 mm, a spindle speed of 12,000 rpm, and a relatively low feed rate.

Depth-dependent energy absorption control of large pulsed electron beam (LPEB) irradiations for defect-free surface modification of metallic alloys

Electron beam surface finishing offers the ability to treat various materials and shapes while enhancing surface properties such as wear and corrosion resistance. However, its industrial application is limited by the formation of crater-like defects' pulse count, irradiation angle, and energy density, were optimized to achieve defect-free surfaces. By systematically investigating the synergistic effects of previously studied parameters (irradiation angle and energy density), the optimal conditions were established through strategic combination of these parameters, demonstrating enhanced surface quality and reduced defect formation. These were compared to previously optimized conditions that focused solely on increasing pulse counts. The new conditions significantly reduced the density of crater-like defects and produced smoother surfaces. This improvement is attributed to concentrated energy absorption near the surface and the creation of a high-temperature gradient, which prevents the introduction of non-metallic inclusions. Unlike conventional methods, where accumulated heat leads to phase transformations and reduces hardness and corrosion resistance, the new approach maintains a rapid cooling rate. This allows the surface to retain a fully martensitic phase even at 45 pulses, resulting in higher surface hardness. These findings highlight that the newly developed conditions not only produce defect-free surfaces but also impart enhanced mechanical properties. This approach suggests that future improvements in surface quality for electron beam-based processes can be achieved by considering adjustments to the irradiation angle and energy density.

Improved mechanical performance and forming accuracy of ZrO2 fixed partial denture based on the digital light processing technology

Fixed partial dentures are the primary treatment for dentition defects. Digital light processing (DLP) 3D printing technology is an advanced technique with significant advantages and potential in the field of dental restoration, particularly in cases requiring high precision and personalization. However, challenges persist in printing fixed partial dentures that meet the strength requirements for clinical applications. In this study, we aimed to optimize printing parameters, including exposure time and layer thickness, to enhance dimensional accuracy, reduce warpage, and improve the surface quality of the samples. Additionally, we focused on the rheological and curing properties of the paste. The optimal combination of printing parameters was found to be 5 seconds of exposure time and 50 μm layer thickness, achieving superior dimensional accuracy, reduced warpage, and improved surface quality. For a slurry with 40% solid content, the dispersant KOS 110 demonstrated the best shear thinning effect, with an optimal addition of 2%. Notably, the Vickers hardness, flexural strength, and fracture toughness of the ZrO2 fixed partial dentures were 13.52 ± 0.21 GPa, 940 ± 20 MPa, and 6.92 ± 0.25 MPa·m1/2, respectively, which surpasses that of human enamel (4 GPa) and is comparable to CAD/CAM ZrO2 (900–1200 MPa). This study demonstrates that DLP technology can be effectively used to fabricate ZrO2 personalized complex fixed partial dentures with excellent mechanical properties and high precision, offering broad application prospects in stomatology.

Sustainable hard machining under zirconia nano-cutting fluid: A step towards a green and cleaner manufacturing process

The present study deals with the machinability (flank wear, surface integrity, cutting temperature and power consumption) and sustainability (Carbon emission and noise emission) investigations during hard machining under dual nozzle assisted novel ZrO2 based nano fluid MQL condition considering Taguchi L27 OA design of experiment. 0.3 % wt. ZrO2 nanofluid MQL medium effectively reduce cutting temperature and found as 65 °C, which shows the effective cooling and lubrication properties of zirconia nanofluid. Improvement in surface quality has been observed with lower rate of flank wear. Depth of cut and feed are found to be the most influential factor affecting power consumption and carbon emission with contribution of 47.213 % and 60.861 % respectively. Noise emission mostly affected by the depth of cut with a contribution of 43.40 %. Optimal parametric condition yields d: 0.1 mm, f: 0.1 mm/rev and v: 80 m/min through WASPAS and sustainable towards manufacturing industries for cleaner hard machining.

Additive manufacturing of polyamide 12 bulk structures using directed energy deposition with a thulium laser: Effect of process conditions on morphology and mechanical performance

Laser-based directed energy deposition of polymers (DED-LB/P) is a highly flexible additive manufacturing process capable of fabricating three-dimensional structures with a high degree of customization on free-form surfaces. In this article, the manufacturability of polyamide 12 bulk structures using DED-LB/P in combination with a thulium laser operating at a wavelength of 1.94 μm is investigated for the first time. The typical absorption bands at this wavelength eliminate the need for additives such as carbon-based nanoparticles, which would limit the range of applications. The generated structures were analyzed regarding porosity, thermal behavior, and mechanical properties to evaluate the potential of DED-LB/P with a thulium laser. As a consequence of the evaporation of absorbed moisture or ethanol residues resulting from powder preparation, a thermal pretreatment of the polymer powder reduced the porosity of the DED-LB/P structures to 0.9%. Depending on the processing parameters, the crystallinity of the produced structures ranged from 25.6% to 29.9%. For the tensile tests, the required geometries were milled from the DED-LB/P bulk structures. The results show that an ultimate tensile strength of up to 52 MPa, an elongation at break of up to 58%, and Young's modulus of up to 1590 MPa can be achieved. These remarkable mechanical properties are primarily attributed to the complete melting of the powder particles in DED-LB/P and the improved surface quality resulting from the milling process.

Effect of manufacturing new U-shaped electrode on die sinking EDM process performance

Traditional electrical discharge machining (EDM) electrodes have several limitations such as long machining time, low material removal rate MRR, hazard emissions and high energy consumption. To overcome these limitations, new electrodes (plane and frame U-shaped) were manufactured considering the electrode manufacturing classifications, such as electrode flushing mechanism, electrode cross-sectional area and electrode bottom machining area. Experiments were performed on a die-sinking EDM machine using copper electrodes and aluminum alloy workpieces. The results were compared with those obtained using the conventional electrode. The newly manufactured electrodes significantly improved the EDM process performance, reducing the machining time by more than 50%, which implies a higher MRR. The reduced machining time also led to lower costs, emissions and energy consumption for efficient EDM processes. Additionally, surface roughness measurements were performed to compare the surface quality of the machined areas using different pulse-code generator systems and electrodes. The results showed an improvement in the machined surface quality when using the new electrodes in comparison with the conventional electrode when using a roughing pulse code generator system.

Surface finishing of 3D-printed Ti–6Al–4 V alloy by electrolyte plasma polishing: Process optimization and microstructure

The electrolyte plasma polishing (EPP) technology is proposed to remove the unmelted powder particles and oxide film for high-quality surface finishing of 3D-printed Ti–6Al–4 V alloy. An orthogonal experiment is conducted to investigate multiple factors that contribute to the surface quality of the alloy during the polishing process. The optimal parameters determined for the EPP process are a voltage of 300 V, a polishing time of 12 min, a polishing depth of 12 cm, and a temperature of 75 °C. Based on the extent of the effect, the factors influencing surface roughness were ranked: voltage > time > depth > temperature. The surface crest and trough area of the alloy is substantially reduced after polishing, while the average roughness experienced a reduction of 76 %. The improvement in surface quality is attributed to the corrosion of the oxide layer by F ions in the electrolytic solution, and the melting of surface protrusions due to the impact of high-energy electrons under high-temperature and high-pressure conditions during plasma discharge. Additionally, the surface hardness of the material decreases slightly, but its corrosion resistance and hydrophobicity are enhanced, and the calibration rate of the EBSD sample can reach 92.51 %, demonstrating that it is an excellent surface finishing technique. Hence, EPP is a promising approach for smoothening 3D-printed metals, especially for alloy parts with complex geometry and porous structure.

A Sustainable Approach-based Optimization of Internal Diamond Burnishing Operation

The related works of the diamond burnishing processes focused on improvements in surface quality. The study aims to optimize burnishing factors, including the spraying distance of the nozzle (S), the inlet pressure of the cold air (I), and the quantity of the liquid CO2 (L) of the cool and cryogenic-assisted diamond burnishing operation for minimizing energy consumed (EC) and arithmetical mean surface height roughness (Sa). Burnishing responses are modeled based on the radial basis function network and full factorial data. The entropy method, improved grey wolf optimizer, non-dominated sorting genetic algorithm II, and technique for order of preference by similarity to ideal solution were implemented to calculate the weights, produce solutions, and select the best outcome. As a result, the optimal data of the S, I, and L were 15.0 mm, 3.0 bar, and 11.0 L/min, respectively. The Sa and EC were reduced by 20.4% and 3.8%, respectively, at the optimality. The optimized outcomes could be employed to improve energy efficiency and machining quality for the internal diamond burnishing process. The optimizing technique could be used to solve complicated issues for different burnishing operations. The cool and cryogenic-assisted diamond burnishing process could be utilized for machining different internal holes.

Study on the effects of ultrasonic vibration-assisted wire-EDM machining parameters on material removal rate and surface roughness of NiTiV shape memory alloy

Nickel-titanium (NiTi)-based shape memory alloys (SMAs) exhibit remarkable properties, making them increasingly demanding in various engineering and medical applications especially when these SMAs are manufactured with intricate shapes and sizes. This present study examines the machining of Ni50Ti48V2 SMA using ultrasonic-assisted WEDM with input parameters of pulse ON time (TON), pulse OFF time (TOFF), peek current (I), and servo voltage (SV) along with 20 kHz constant ultrasonic vibration on the responses of material removal rate (MRR) and surface roughness (Ra). RSM-BBD response surface methodology was used to conduct the experiments. It was inferred from analysis of variance (ANOVA) analysis, that as the peak current (I) and pulse ON time (TON) increased, the MRR increased by 65.76% and Ra decreased by 54.44%. The confirmation was carried out in USV-WEDM under optimal conditions, which shows that both the predicted and actual MRR and Ra are close to each other. When compared with conventional WEDM, the USV-WEDM shows significant improvement in MRR by 8.6% and also improved surface quality by 6.3%. The surface characteristics of Ni50Ti48V2 after machining were examined using field-emitted scanning electron microscopy, showing small irreularisation peaks and wavy surface topography at optimised parameter conditions. USV-WEDM showed a lower-order micro-hardness variation due to effective flushing of molten layer re-accumulation as compared to WEDM. When comparing the base and machined samples, the temperatures of austenite and martensite are nearly the same, indicating that shape memory effects are unaffected by the USV-WEDM process.

Studies on surface roughness and axial thrust force of drilled holes in Mg-Zn-Ca bio-medical alloy

Mg-Zn-Ca alloy is a promising candidate for orthopaedic implants such as bone plates and screws, as it has a similar mechanical strength and elastic modulus to bone, and it degrades in the body without causing toxicity or inflammation. Drilling studies are necessary to optimize the drilling process parameters, to evaluate the machinability and surface integrity of Mg-Zn-Ca alloy, and to ensure the effective and efficient drilling for various applications in the medical and engineering fields. The present experimental study emphasizes the influence of Ca content, biofriendly coolants and their combined effect with standard drill bits on the surface quality and axial thrust force in the drilling operation of Mg-Zn-Ca alloy. The drilling parameters such as cutting speed, feed rate, standard tools, bio-compatible coolants were optimized with respect to the amount of Ca in the Mg-Zn alloy. The axial thrust force and average surface roughness of drilled holes were considered as response of the experiments. The drilled surfaces were measured for average surface roughness in the transverse direction along the centre path of the drilled hole and a qualitative analysis was also carried out using advanced confocal microscope. The results revealed that the cutting speed among continuous factors significantly influenced the axial thrust force and average surface roughness. The effect of categorical factors was assessed using a regression based ranking method. The results of statistical analysis revealed that high speed steel, and vegetable oil offered improved surface quality, whereas the coconut oil showed low axial thrust force. The liquid nitrogen showed high value of axial thrust force and average surface roughness due to the brittleness induced by cryogenic coolant before drilling operation.

Effect of stage gas nitriding on corrosion and wear resistance of Ti6Al4V alloy in physiological environment

The wear and corrosion resistance of the Ti6Al4V alloy after gas nitriding combined with stage heat treatment was studied in the physiological environment. It was shown that nitriding temperature at the first stage of the heat treatment mainly effects on the surface quality and microhardness of the treated alloy. The corrosion behaviour of the nitrided Ti6Al4V alloy was studied in Ringer's solution, which simulates the physiological environment of human body. It was shown that the corrosion resistance of the alloy is enhanced by increasing thickness and TiN content in the nitride layer, and improving surface quality. The tribological characteristics of the nitrided Ti6Al4V alloy in a tribo-pair with PE-UHMW were evaluated in a 10 % aqueous solution of chondroitin sulfate, which simulates the synovial fluid. It was established that reducing nitriding temperature at the first stage of the heat treatment improved the wear resistance of the treated alloy due to decrease of the surface roughness and microhardness.

Environmentally Friendly Chemical–Magnetorheological Finishing Method for Ti–6Al–4V Biological Material Based on Fe3O4@SiO2, Oxaloacetate Acid and H2O2

Titanium alloy is extensively utilised in various advanced equipment across multiple industries, especially in biological implantable devices. The surface machining of such devices is required to provide a finished surface with high precision and gloss. This study presents an established ecofriendly slurry for a hybrid polishing process utilising a highly efficient chemical and magnetorheological fluid (C-MRF) to obtain ultraprecise surface quality. This slurry incorporated Fe3O4@SiO2 abrasive particles, oxaloacetate acid (C4H6O5), deionised water and hydrogen peroxide (H2O2) as an oxidiser. Ti–6Al–4V workpieces polished with C-MRF based on Fe3O4@SiO2 abrasives and polishing performance were used to investigate the influence of the oxidising agent H2O2 and oxaloacetate acid (monitored with a pH indicator) on the surface finish of Ti–6Al–4V biomaterial. In contrast to the traditional mechanical and chemical polishing methods for titanium alloys that often include strong bases and acids along with chemicals that endanger the environment and humans, the proposed polishing process based on the newly developed ecofriendly magnetic composite leveraged the advantages of magnetorheological fluid with chemical reactions to create an ultra smooth surface. Experiments were performed to investigate the influence of different polishing durations and factors on the quality of polished surfaces, thereby optimising technological parameters, reducing time and improving surface quality. Various technological parameters were evaluated through single-factor and orthogonal experiments to assess their distinct effects on surface quality and material removal capability. This work proposed an environmentally friendly C-MRF method for finishing Ti–6Al–4V biomaterial with high efficiency and industrial applicability.