Magnetorheological Finishing Process Research Articles

A Hybrid Electrochemical Magnetorheological Finishing Process for Surface Enhancement of Biomedical Implants

Abstract The proposed novel polishing method, hybrid electrochemical magnetorheological (H-ECMR) finishing, combines electrochemical reactions and mechanical abrasion on the workpiece surface to reduce finishing time. Moreover, H-ECMR finishing on the biomaterial surface produces a uniform, thick passive oxide layer to improve corrosion resistance. Herein, the electrolytic solution facilitates the chemical reaction and acts as a carrier medium for carbonyl iron particles (CIPs) in magnetorheological (MR) fluid. The synergic action of the two processes reduces the surface finishing time, which takes longer in the case of the conventional magnetorheological Finishing (MRF) process, as observed experimentally. The developed H-ECMR finishing process employs an electromagnet, maneuvering in situ surface quality variation by altering the magnetic field during finishing. The magnetic shield material (i.e., mu-metal) confines the bottom of the electromagnet core to restrict the magnetic field's leakage and provide a uniform and concentrated magnetic field at the polishing spot. The effectiveness of the H-ECMR process is evaluated based on various surface roughness parameters (i.e., average surface roughness (Ra), skewness (Rsk), and kurtosis (Rku)) and compared with the MRF process. A 96.4% reduction in Ra value is attained in the H-ECMR polishing compared to 49.6% in MRF for identical polishing time. Furthermore, an analytical model is developed to evaluate the final Ra attained from the developed H-ECMR polishing process and agrees well with the experimental results. The impact of different process parameters on surface roughness values is also analyzed. The electrochemical reaction forms a thick and unvarying passive layer on the Ti–6Al–4V surface as layer thickness increases to 78 nm from 8 nm. A case study on the femoral head of the Total Hip Arthroplasty (THA) for enhancement in the surface roughness and biocompatibility is performed through the developed H-ECMR polishing. The Ra value is decreased to 21.3 nm from 326 nm on the femoral head surface through the contour-parallel radial toolpath strategy.

Design and frequency control study of small-sized magnetorheological finishing device applied in optical manufacturing

With the continuous development of various advanced optical systems, there is an increasing demand for optical components with small apertures (generally ranging from a few millimeters to tens of millimeters in diameter), steep slopes, or even specific relief structures on their surfaces (such as continuous phase elements). These optical components all require high surface quality and shape accuracy. However, existing magnetorheological finishing (MRF) devices have larger dimensions, and the obtained removal function size is relatively larger than the size of small-diameter optical components, making it difficult to achieve high surface shape accuracy after processing. To achieve high-precision machining of small-aperture optical components and obtain higher frequency control capabilities, this study first designed and optimized a small-size MRF device with a 13 mm polishing wheel. Based on theoretical and finite element simulation analyses, the magnetic pole structure of the small-size MRF device was designed. The orthogonal experimental method was used to optimize the key parameters of the magnetic pole according to the magnetic field design requirements, and the device was constructed. Its performance and stability were experimentally analyzed, and the results showed that the peak magnetic field intensity in the polishing area of the device was about 230mT, which met the polishing requirements, and both its long-term and short-term processing stabilities met the design requirements. In addition, different sizes of removal functions were analyzed for frequency control ability, and theoretical and spectral analyses of the removal function indicated that the small-size removal function had better low-frequency error correction ability, while for mid-frequency band and mid-frequency ripple error, the opposite was true. The experimental results showed that when the optical component was shaped by 20 %, the low-frequency convergence capability of the 100 mm polishing device was only 18.72 %, much lower than that of the 13 mm polishing device, which was 52.51 %.Moreover, the mid-frequency ripple spectrum amplitude for the 13 mm polishing device was more than 15 times higher than that for the 100 mm polishing device when removing 50 nm material, and the mid-frequency root mean square (RMS) increased significantly, deteriorating the surface mid-frequency error of the optical component. Therefore, when performing magnetorheological polishing on an optical component surface, a process of using large-size MRF devices for roughing combined with small-size MRF devices for finishing can ensure machining efficiency while controlling low-frequency and mid-frequency errors well. This study provides theoretical support for the magnetic pole design of MRF devices and broadens the frequency spectrum correction ability and application range of MRF processes, which has great application value.

Surface topography assessment using chemical assisted ball end magnetorheological finishing

The generation of residual stresses by grinding process on the surface for a soft material result in poor performance and diminished life. Ball end magnetorheological finishing (BEMRF) process is a recently developed process that is effectively used for fine figuring and polishing of a variety of magnetic and non-magnetic materials. In this paper, grinding-induced residual stresses are addressed, and an attempt is made to relieve these residual stresses while achieving high surface finish using chemical assisted ball end magnetorheological finishing (CA-BEMRF) process. The chemical used in the present work is applied first time in BEMRF process and aluminium 7075 alloy workpiece has not been finished with this novel finishing process. The impact of various CA-BEMRF variables on percentage surface roughness reduction and percentage reduction in residual stresses are discussed statistically and graphically. Residual stresses of workpiece surfaces have been measured by using portable x-ray residual stress analyzer. Scanning electron microscopy (SEM) and atomic force microscopy (AFM) of the finished workpiece before and after CA-BEMRF process is carried out to assess the effects of magnetizing current, tool rotation and working gap on surface topography of machined surface. It has been observed that reduction in residual stress is achieved along with high surface finish on aluminium workpiece surface using CA-BEMRF technique. Significant process parameters affecting the residual stresses and surface roughness during polishing of workpiece are obtained using Analysis of variance (ANOVA) and F-test. The optimization problem for maximum percentage reduction in surface roughness and maximum percentage reduction in residual stress is formulated as multi objective, multi variable, nonlinear optimization problem. Maximum percentage surface roughness reduction and minimum residual stress has been found at magnetizing current 2.3 A, rotational speed of tool 550 rpm and working gap of 0.5 mm. Confirmatory experimental tests have been conducted and results obtained were found very close to the predicted outcome.

Research on the influence of the non-stationary effect of the magnetorheological finishing removal function on mid-frequency errors of optical component surfaces.

With the continuous development of modern optical systems, the demand for full spatial frequency errors of optical components in the system is increasing. Although computer-controlled sub-aperture polishing technology can quickly correct low-frequency errors, this technology significantly worsens the mid-frequency errors on the surface of the component, which greatly inhibits the improvement of optical system performance. Therefore, we conducted in-depth research on the non-stationary effect of the removal function caused by the fluctuation in magnetorheological polishing and their influence on the mid-frequency errors of the component surface. We established a non-stationary profile model of the removal function and applied this model to simulate the distribution of mid-frequency errors on the surface of the processed component, considering the non-stationary effect. The simulation results showed that the non-stationary effect of the removal function weaken the mid-frequency ripple errors but increase other mid-frequency errors. Therefore, we first proposed the optimal single-material removal thickness corresponding to the non-stationary effect and experimentally verified the effectiveness of the optimal material removal thickness in suppressing mid-frequency errors. The experimental results showed that when the magnetorheological finishing single-material removal thickness is set to the optimal value, both the mid-frequency ripple errors and the mid-frequency RMS on the surface significantly decrease. Therefore, this work provides a basis for improving the existing magnetorheological finishing process and effectively suppressing the mid-frequency errors on the surface of processed components. It also provides theoretical and technical support for the magnetorheological processing and manufacturing of high-precision optical components. At the same time, the non-stationary effect and the corresponding analytical models has the potential to be extended to other polishing tools.

Improved CNC ball-end magnetorheological finishing process for borosilicate glass polishing

ABSTRACT This research aims to present an improved design of the Ball-End Magnetorheological Finishing (BEMRF) tool with the capability of being mounted on a CNC milling machine for polishing borosilicate glass (Bk7) lenses. Subsequently, the new BEMRF tool was designed, researched, and adjusted with magnetostatic simulation in Ansys Maxwell software. A response surface method experimental investigation was conducted to discover the optimized constitution of the magnetorheological fluid’s abrasive and carbonyl iron particles used for finishing operation on flat Bk7 glass. The simulation results and afterward measurements with a Gauss meter showed that changes in the BEMRF tool improved the variation in the density of magnetic flux in the polishing gap. At the optimum fluid constituents of 16 vol% abrasives and 29 vol% carbonyl iron particles, a 59% improvement in surface roughness was achieved. The proposed CNC tool found an appropriate way to finish Bk7 glass.

Surface Enhancement of Additively Manufactured Bone Plate Through Hybrid-Electrochemical Magnetorheological Finishing Process

Additive manufacturing or 3D printing provides the benefits of individualizing the implant per patient requirements. However, the poor surface quality of additively manufactured biomaterial is a major limitation. Hence, hybrid-electrochemical magnetorheological (H-ECMR) polishing is developed to improve the surface quality of fabricated parts. H-ECMR finishing is an advanced surface polishing operation that avails the synergic action of mechanical abrasion and the electrochemical reaction to enhance the surface quality of the workpiece without hampering its surface topography. Furthermore, the developed H-ECMR finishing process reduces the finishing time and produces a uniform surface quality compared with the conventional magnetorheological (MR) finishing process. However, the surface finishing of the parts having a hole-of-pocket feature through the H-ECMR finishing process is a major challenge as MR fluid gets trapped inside those holes or pockets. A feature-based hybrid H-ECMR finishing process is developed to resolve the issue. In this case, paraffin wax is applied to the holes and pockets before the H-ECMR process occurs. In the present work, bone plates are fabricated through selective laser melting, and their surface quality is further enhanced through the H-ECMR finishing process. Bone plates are necessary to provide mechanical stability during bone fracture healing by adapting to the chemical environment. The final Ra value of 21.37 nm is attained from 9.36 μm through H-ECMR finishing. Pin-on-disk study is carried out on the biomaterial to analyze its wear resistance. The surface topography of the workpiece is analyzed through scanning electron microscopy before and after finishing, and it was observed that a uniform surface is achieved after polishing. Apart from the average surface roughness (Ra), other roughness parameters such as skewness (Rsk) and kurtosis (Rku) are analyzed to study the attribute of the surface irregularities.

Experimental investigations on chemo-mechanical magneto-rheological finishing of Al-6061 alloy using composite magnetic abrasive (CIP-Al2O3) developed via microwave-sintering route

Magneto-rheological (MR) fluid-based surface finishing techniques rely heavily on simply mixed magnetic abrasives due to their ease of preparation. The abrasive particle's in a slurry begin to fly out from the finishing region during the surface finishing process because of the high centripetal force caused by the magnet rotational speed, reducing the process's effectiveness. To fill this void, a new CIP-Al2O3 composite magnetic abrasive is being developed via microwave sintering and proposed for the chemo-mechanical magneto-rheological finishing (CMMRF) process for their extensive performance evaluation. The composite magnetic abrasive (CIP-Al2O3) abrasive's structural and phase composition findings suggest that Al2O3 grains are tightly embedded and have strong attractive strength among the particles. The developed CIP-Al2O3 abrasives also possess the required magnetization and rheological properties for surface finishing. The experiments are carried out using a central composite design and ANOVA to correlate the output response (surface roughness and material removal rate) and parametric variables (tool speed, work-gap, and finishing time) in the CMMRF of Al-6061 alloy. A damage-free Al surface with surface qualities of Ra 59 nm is obtained after processing by CMMRF for 1 h. The rate of material removal was steadily increased to 0.379 mg/min by these magnetic abrasives. Comparing the composite magnetic abrasives' results to those with simply mixed abrasives, there is a significant improvement of 34 % in Ra value and 50 % in MRR.

Research on the mechanism of particles separation in magnetorheological fluid-based finishing process

Magnetorheological fluid-based finishing is one of the recognized techniques for precisely finishing of a variety of components. Material removal depends largely on velocity and compression of the magnetorheological (MR) fluid ribbon when it interacts with the workpiece. This article studies the throwing of magnetic and abrasive particles during carrier wheel rotation. Theoretically computed centrifugal and magnetic forces are balanced against each other to determine the speed at which these particles are ejected from the MR fluid. The results of experiments at various carrier wheel speeds show the reduction of MR fluid ribbon thickness at higher wheel speed due to throwing of MR fluid. As a result of particle separation from the MR fluid at high rotational speed. As the carrier wheel speed increases, surface roughness decreases initially and then increases. There is good agreement between theoretical and actual results for the spindle speed at which magnetic particles depart the MR fluid ribbon.

Investigation of Process Parameters of a Novel Magnetorheological Finishing Process for External Cylindrical Surfaces

The recent rise in the demand for high precision, close tolerances, and super surface finish quality of components and part assembly modules in the competitive manufacturing industrial environment for the enhanced working life and functional requirements of machines globally. Three revolving curved tip tools based magnetorheological process is designed and developed to fine finish the external cylindrical surfaces of soft and hard materials. The effect of the key operational machining parameters on the surface roughness of a newly developed magnetorheological process was carried out using a one factor at a time method. The magnetizing current, the revolving speed of the tools, the rotational speed of the workpiece, workpiece traverse speed are the parameters that have been considered for this purpose. The experimentation has been performed on the aluminium workpiece because of its broad applicability, such as manufacturing shafts, rods, pistons, and other circular components. The primary purpose of this study was to determine the range of essential control parameters for the newly developed finishing process. The percentage reduction in Ra, Rq, and Rz values are 69.64%, 58.21%, and 54.48%, respectively, after 60 minutes of finishing at magnetizing current 2A, the revolving speed of the tools 30 RPM, the rotation speed of the workpiece 600 RPM and feed 10 cm/min.

Parametric investigation and optimization of revolving tools-based magnetorheological finishing process for external cylindrical surface of printing machine roller made of copper

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 μm from the initial values of 0.375, 0.527, and 1.96 μm, 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.

Computer-aided process planning system for super finishing of flat surfaces with pockets through magnetorheological finishing process

ABSTRACT Magnetorheological Finishing (MRF) process is an advanced surface finishing operation that provides mirror-like polished surfaces required for the implants, lenses (telescope, microscope, etc.), miniature parts, etc. for their enhanced functionality. However, various features (including holes and pockets) on the workpiece surface produce a challenge during their polishing through the MRF process; the Carbonyl Iron Particles (CIPs) chains get trapped inside the holes during the finishing operation and generate irregular surface quality on the polished surface. This paper outlines a Feature-based Hybrid MRF Planning System (FHMRF-PS) developed on the geometrical data inputs to produce automated process planning for the paraffin wax deposition into the hole and pocket features of the workpiece before MRF. An external module is developed to deposit paraffin wax in the holes and pockets to ensure a uniform finish over the targeted surface. Herein, appropriate toolpath strategies are included for the deposition and MRF process to enhance finishing efficiency. Furthermore, a case study on a bone plate made of Ti-6Al-4 V is performed to analyze the efficiency and effectiveness of the developed FHMRF-PS. The initial surface roughness (R a ) value of 324.12 nm is reduced to 21.56 nm after the proposed process planning during MRF. The impact of underfilling and overfilling of paraffin wax on the surface quality of the polished surface is also analyzed in the present study. Further, the uniformity of the surface roughness over the MRF polished surface is compared with and without paraffin wax deposition inside the workpiece’s hole and pocket features. It is found that paraffin wax deposition helps to produce uniform surface quality.

Ultrasonic vibration–assisted magnetorheological hybrid finishing process for glass optics

Ultrasonic vibration–assisted magnetorheological hybrid finishing process for glass optics

A novel magnetorheological finishing process based on three revolving flat tip tools for external cylindrical surfaces

The magnetorheological finishing technique based on a stationary curved tip tool is found less effective in finishing external cylindrical surfaces. Therefore, three revolving flat tip tools-based magnetorheological finishing process which utilises the rotation of both workpiece and tools have been developed to address the issues of the existing method. Also, a feed mechanism has been built to provide the longitudinal movement to the workpiece. A workpiece of mild steel has been finished by both developed and existing methods. It has been observed that after finishing 1 hour 30 minutes with a stationary curved tip tool, surface roughness values Ra, Rq, and Rz decrease by 69.29%, 64.41%, and 61.26%, respectively. Whereas, the reduction in the surface roughness value of Ra, Rq, and Rz by 85.38%, 84.51%, and 82.7%, respectively, have been noted after finishing with the three revolving flat tip tools process at the same parameters and conditions.

Magnetorheological Finishing of Chemically Treated Electroless Nickel Plating

Electroless nickel plating with a nanofinished surface is used in space mirrors, automobile parts, aircraft components, optical instruments, and electronic equipment. Finishing of these components using conventional finishing techniques is limited due to size, shape, material, and process constraints. This work reports the nanofinishing of electroless nickel-plated surfaces using a magnetorheological finishing process where the surfaces are pre-treated with chemicals. The chemicals used in this work are hydrogen peroxide (H2O2) and hydrofluoric acid (HF). The effect of exposure time and concentration on the microhardness and roughness is studied to understand the surface chemistry after chemical treatment. The hydrogen peroxide forms a passivated layer, and it helps in easy material removal. Hydrofluoric acid improves surface quality and also helps in the removal of contaminants. The finished surface is characterized to understand the effect of chemical treatment on the finishing rate and surface topography. Normal and tangential forces are mainly affected by the hardness and surface condition after the chemical treatment. The best combination of parameters (chemical treatment with 1% HF for 30 min) was obtained and finishing was carried out to obtain a nanofinished surface with its areal surface roughness (Sa) reduced to 10 nm.

Prediction of surface roughness and the material removal rate in magnetorheological finishing.

Magnetorheological finishing (MRF) is a sub-aperture polishing process, which is often used to correct surface errors and remove sub-surface damage after grinding. A strong correlation exists between the material removal rate and surface roughness in MRF, but current theoretical models are incapable of predicting these two factors at the same time. In this paper, a theoretical model was developed to describe the material removal rate and surface quality after MRF in order to better understand the material removal mechanism of MRF and explain the relationship between surface roughness and material removal rate. Two modes of experiments (uniform polishing and fixed point polishing) were conducted on monocrystalline silicon to obtain the results of surface roughness and removal rate. The experimental results are highly consistent with the theoretical model calculated results. The theoretical model could be a reference for high-efficiency and ultra-smooth MRF process.

Development of magnetic nanoparticle based nanoabrasives for magnetorheological finishing process and all their variants

Efficacy and the outcome of the magnetorheological finishing (MRF) related processes depends on two crucial factors, (i) a finishing abrasive and (ii) a magnetic particle. However, the magnetic particles although necessary, become a hindrance for non-magnetic abrasive particles in directly reaching the surface to be finished. This study relates to the development of SPION-based smart material for MRF and all their variant processes. The SPION particles possess dual nature such as nanoabrasives and magnetic nanoparticle. The superparamagnetic property of the developed SPION particle has been confirmed by alternating gradient magnetometer with the saturation magnetization value of 82.23 emu/g. The polishing performance of the developed SPION-based particle as abrasive has been investigated on a BK-7 optical glass and the polishing is done via a 5-axes automated ball end magnetorheological finishing (BEMRF). The developed SPION abrasive enhanced the finishing process of the BEMRF technique and provided surface finishing on the BK-7 substrate up to the surface roughness (Ra) values of 22.3 nm with the Ra improvement of 88.14%.

Effect of sintering routes on CIP/EIP – Al2O3 composite magnetic abrasive for chemo-mechanical magneto-rheological finishing of aluminium 6061

In magnetorheological fluid-based finishing processes, the lower gripping of abrasives in between ferromagnetic particle’s chain structure limits its finishing speed, resulting in a lower material removal rate and desired surface standard. In addition, tool ageing has significantly impacted these finishing processes at a higher speed. To improve the efficiency of finishing processes, composite magnetic abrasives are fabricated by using powder metallurgy techniques via both microwave and conventional processing (sintering) routes. Comparison studies were performed on these samples based on ferromagnetic materials (CIPs and EIPs) used and sintering at 950°C under fixed element composition. A newly advanced chemo-mechanical magneto-rheological finishing (CMMRF) process for aluminium alloy surface polishing was also proposed, combining mechanical abrasion and chemical action for the performance evaluation of composite magnetic abrasives. Most notably, the microwave processed composite magnetic abrasive outperformed conventionally processed samples in terms of magnetic and rheological properties. The composite magnetic abrasives significantly increased the rate of material removal from the metal surface while reducing the tool ageing effect. The surface profile and observation show that a nearly defect-free surface was produced at higher speeds using these composite magnetic abrasives compared to simply mixed abrasives based results.

A study on in-vitro behaviour of stainless steel 316L subjected to rotational magnetorheological abrasive flow finishing process

In Rotational Magnetorheological Abrasive Flow Finishing (R-MRAFF) process, Magnetic Field Intensity (MFI) is the primary factor for the formation of ferrous chains which is responsible for finishing. Changing the pole distance between magnets to achieve a difference in MFI values will alter the strength of the ferrous chains. In this study, three different MFI values such as 0.34, 0.36, and 0.40 Tesla were chosen for finishing on Stainless Steel 316L (SS 316L). Surface wettability, bio-corrosion, and hemocompatibility studies were conducted to investigate the in-vitro behavior of SS 316L. The wettability of the implants changed from hydrophobic (100.92°) to hydrophilic (83.452°) surface as the MFI value increased. Bio-corrosion studies revealed improved corrosion resistance for R-MRAFF process finished samples, with the corrosion rate reduced from 3.693 to 0.967 μm year−1. Hemocompatibility of SS 316L was improved with reduced platelet adhesion when compared to the pristine sample.

Understanding the Mechanism of Abrasive-Based Finishing Processes Using Mathematical Modeling and Numerical Simulation

Recent advances in technology and refinement of available computational resources paved the way for the extensive use of computers to model and simulate complex real-world problems difficult to solve analytically. The appeal of simulations lies in the ability to predict the significance of a change to the system under study. The simulated results can be of great benefit in predicting various behaviors, such as the wind pattern in a particular region, the ability of a material to withstand a dynamic load, or even the behavior of a workpiece under a particular type of machining. This paper deals with the mathematical modeling and simulation techniques used in abrasive-based machining processes such as abrasive flow machining (AFM), magnetic-based finishing processes, i.e., magnetic abrasive finishing (MAF) process, magnetorheological finishing (MRF) process, and ball-end type magnetorheological finishing process (BEMRF). The paper also aims to highlight the advances and obstacles associated with these techniques and their applications in flow machining. This study contributes the better understanding by examining the available modeling and simulation techniques such as Molecular Dynamic Simulation (MDS), Computational Fluid Dynamics (CFD), Finite Element Method (FEM), Discrete Element Method (DEM), Multivariable Regression Analysis (MVRA), Artificial Neural Network (ANN), Response Surface Analysis (RSA), Stochastic Modeling and Simulation by Data Dependent System (DDS). Among these methods, CFD and FEM can be performed with the available commercial software, while DEM and MDS performed using the computer programming-based platform, i.e., “LAMMPS Molecular Dynamics Simulator,” or C, C++, or Python programming, and these methods seem more promising techniques for modeling and simulation of loose abrasive-based machining processes. The other four methods (MVRA, ANN, RSA, and DDS) are experimental and based on statistical approaches that can be used for mathematical modeling of loose abrasive-based machining processes. Additionally, it suggests areas for further investigation and offers a priceless bibliography of earlier studies on the modeling and simulation techniques for abrasive-based machining processes. Researchers studying mathematical modeling of various micro- and nanofinishing techniques for different applications may find this review article to be of great help.

Design and development of ultrasonic assisted-rotational magnetorheological abrasive flow finishing (UA-RMRAFF) process

The rotational-magnetorheological abrasive flow finishing (R-MRAFF) process, as one of the derivatives of the abrasive flow finishing (AFF) process, has a high potential for surface modification. However, the R-MRAFF process is a major challenge in terms of finishing time. The present study aims to propose ultrasonic vibration has been proposed as a technical solution to deal with the technological challenges of the R-MRAFF process. A new finishing method called the ultrasonic assisted-rotational magnetorheological abrasive flow finishing (UA-RMRAFF) process has been developed for the first time in which ultrasonic vibrations are applied to the workpiece perpendicular to the magnetorheological polishing (MRP) fluid flow direction. For this purpose, the workpiece was first kept in dynamic condition. Then, an ultrasonic horn was designed using the finite element method (FEM) to apply maximum amplitude to the workpiece. To evaluate the finishing efficiency of the UA-RMRAFF process, experiments were conducted on the internal finishing of Al2024 tubes at different finishing times for investigating and observing its effect on surface roughness (Ra) and material removal (MR). In addition, a comparative study was performed between the UA-RMRAFF and R-MRAFF processes in terms of % change in Ra (%ΔRa) and % improvement in MR. Experimental findings illustrate that the UA-RMRAFF process provides a uniform and fine surface finish without surface defects such as a mirror up to the range of 25.5 nm, in addition to increasing MR. Based on the results of the comparative study, the UA-RMRAFF process performs surface modification faster than that of the R-MRAFF process. While confirming these findings, the morphological and topographic analysis of the surface of the finished samples emphasizes that the main difference between the UA-RMRAFF and R-MRAFF processes is in the sinusoidal motion path of abrasive particles on the workpiece surface asperities, which clearly shows the effect of ultrasonic vibrations.