Workpiece Surface Research Articles

Coupling effect of machine tool dynamic characteristics and cutting conditions on the cutting process vibration and high-speed micro-planing surface mid-frequency waviness

In addition to the dynamic characteristics of the machine tool, cutting conditions significantly influences the vibration of the cutting system and mid-frequency waviness of the workpiece surface in ultra-precision machining (UPM). In this work, the effects of cutting conditions on machining vibration and surface waviness were investigated by high-speed micro-planning experiments. The origin of vibration and waviness were elucidated by frequency-domain processing of the vibration signal and surface waviness analysis. The dynamic characteristics of machine tool are determined using modal test and analysis. The results revealed that the cutting force has different contributions to the workpiece vibration and tool vibration. In the time domain, distinct differences can be found in stability and attenuation of various waviness components. The divergent effects of cutting force components in different vibration forms are confirmed through a novel cutting force model of micro-planing. The investigation can further reveal the formation mechanisms of cutting system vibration and surface waviness during the micro-cutting process, which can provide practical guidance for suppressing mid-frequency waviness on machined surfaces.

Identification and classification of surface defects for digital twin models of the workpiece.

Workpiece surface defect detection is an indispensable part of intelligent production. The surface information obtained by traditional 2D image detection has some limitations due to the influence of environmental light factors and part complexity. However, the digital twin model has the characteristics of high fidelity and scalability, and the digital twin surface can be obtained by a device with a scanning accuracy of 0.02mm to achieve the representation of the real surface of the workpiece. The surface defect detection system for digital twin models is proposed based on the improved YOLOv5 model in this paper. Firstly, the digital twin model of the workpiece is reconstructed by the point cloud data obtained by the scanning device, and the surface features with defects are captured. Subsequently, the training dataset is calibrated based on the defect surface, where the defect types include Inclusion, Perforation, pitting surface and Rolled-in scale. Finally, the improved YOLOv5 model with CBAM mechanism and BiFPN module was used to identify the surface defects of the digital twin model and compare it with the original YOLOv5 model and other common models. The results show that the improved YOLOv5 model can realize the identification and classification of surface defects. Compared with the original YOLOv5 model, the mAP value of the improved YOLOv5 model has increased by 0.2%, and the model has high precision. On the basis of the same data set, the improved YOLOv5 model has higher recognition accuracy than other models, improving 11.7%, 3.4%, 6.2%, 33.5%, respectively. As a result, this study provides a practical and systematic detection method for digital twin model surface during the intelligent production process, and realizes the rapid screening of the workpiece with defects.

Texture feature similarity-based roughness intelligent evaluation: a case study applied to milled surfaces

Surface roughness is of great significance in maintaining mechanical performance and improving the reliability of the equipment. However, fast surface roughness evaluations that are sufficiently stable and efficient for engineering in situ use have not yet been realized. To address this issue, an image-driven roughness intelligent method is proposed in this research. By evaluating the texture similarity intelligently between the testing image and the reference image, the surface roughness of the testing image can be acquired. Firstly, with a proposed adaptive texture extraction method, the texture feature of an image can be extracted even under a complex background. Secondly, by establishing the graph structure of the texture grayscale features, the similarity between different images is evaluated. Finally, by establishing a sparrow-optimized support vector machine regression method, the mapping relationship between the similarity and the surface roughness can be acquired. The experimental results indicate that the proposed method for intelligent evaluation of roughness has superior prediction performance (the average relative prediction error of Ra and Rz are 8.8156% and 8.0571%, respectively). Therefore, this work provides a useful tool for non-contact detection of workpiece surface roughness.

Research on the trajectory planning and global optimization strategy of cold spraying technique for complex products coating preparation

PurposeThis paper aims to present a set of processes for obtaining the global spraying trajectory of a cold spraying robot on a complex surface.Design/methodology/approachThe complex workpiece surfaces in the project are first divided by triangular meshing. Then, the geodesic curve method is applied for local path planning. Finally, the subsurface trajectory combination optimization problem is modeled as a GTSP problem and solved by the ant colony algorithm, where the evaluation scores and the uniform design method are used to determine the optimal parameter combination of the algorithm. A global optimized spraying trajectory is thus obtained.FindingsThe simulation results show that the proposed processes can achieve the shortest global spraying trajectory. Moreover, the cold spraying experiment on the IRB4600 six-joint robot verifies that the spraying trajectory obtained by the processes can ensure a uniform coating thickness.Originality/valueThe proposed processes address the issue of different parameter combinations, leading to different results when using the ant colony algorithm. The two methods for obtaining the optimal parameter combinations can solve this problem quickly and effectively, and guarantee that the processes obtain the optimal global spraying trajectory.

Study on magnetohydrodynamic internal cooling mechanism within an aluminium oxide cutting tool

One of the challenges in the transfer of heat during the mechanical machining process is the coolant substance used in the internal cooling method which is generally liquid water or a water-based coolant. This limits the heat transfer capacity insofar as the thermal conductivity of liquid water is concerned. The other difficulty is the requirement for an external mechanical system to pump the coolant around the internal channel, providing efficient transfer of the accumulated thermal energy. This study proposes a novel method to address this issue by using liquid gallium which provides the means to transfer the excess heat generated during the cutting process by integrating the design into an aluminium oxide insert. Combining this with a magnetohydrodynamic drive, the coolant system operates without the need for mechanical input. Liquid gallium is nontoxic and has a much higher thermal conductivity over liquid water. Investigations of the novel cooling system is performance compared against liquid water through numerical modelling, followed by an experimental machining test to ascertain the difference in heat transfer effectiveness, tool wear rates and workpiece surface finish when compared to dry machining and external cooling conditions on stainless steel 316L. Without cooling, experimental machining tests employing a cutting speed of Vc = 250 m min−1 resulted in a corner wear VBc rate of 75 μm, and with the magnetohydrodynamic-based coolant on, produced a VBc rate of 48 μm, indicating a difference of 36% in relative tool wear under the same cutting conditions. Increasing the cutting speed Vc to 900 m min−1, produced a corner wear VBc rate of 357 μm without the active coolant and a VBc rate of 246 μm with the magnetohydrodynamic-based coolant on, representing a decrease of 31% in relative tool wear. Further tests comparing external liquid water cooling against the liquid gallium coolant showed at Vc = 250 m min−1, a difference of 29% in relative tool wear rate reduction was obtained with the internal liquid gallium coolant. Increasing the cutting speed to Vc = 900 m min−1, the data indicated a difference of 16% relative tool wear reduction with the internal liquid gallium. The results support the feasibility of using liquid gallium as an internal coolant in cutting inserts to effectively remove thermal energy.

An Investigation of Real-Time Robotic Polishing Motion Planning Using a Dynamical System

When addressing the technical challenges of achieving precise force tracking during the local polishing process of polishing robots, controlling the contact state between the robot and the workpiece surface is essential. To this end, a contact motion-planning strategy based on dynamic systems is designed to generate trajectory routes during local polishing. The trajectory simulation of the local modulation dynamic system is achieved through the employment of the support vector regression (SVR) algorithm with a Gaussian kernel, facilitating the learning process. The feasibility and stability of planning local paths are validated using the local modulation dynamic system. To maintain a constant contact force between the end-effector polishing robot and the workpiece, an integral adaptive impedance control strategy is utilized, enabling the robot’s compliant control. Subsequently, an experimental system for the polishing robot is constructed in order to verify the effectiveness of the motion-planning system. The experimental results demonstrate that the proposed motion-planning approach is applicable in practical polishing processes, ensuring smooth contact and maintaining the desired contact force when scanning nonlinear surfaces, and thus showcasing stability and practicality.

Quality control of NiCr-Cr3C2-hBN@Ni coating on thin-walled GH4169 alloy surface prepared by plasma spraying

As equipment lightweight trends progress, thin-walled structures have seen extensive application in critical aerospace components. Nevertheless, the aero-engine tail nozzle flaps are exposed to the harsh operating conditions of high-temperature friction, so there is an urgent requirement to prepare wear-resistant, self-lubricating coatings with a wide range of temperatures for their protection. Due to the poor rigidity and weak strength of thin-walled workpieces and complex forms of structural stresses, the processing is extremely difficult. In order to solve the thermal deformation problem of coating workpieces prepared by spraying on the surface of thin-walled workpieces, the effects of spraying path, cooling airflow, and spraying interval on the thermal force field of thin-walled workpieces to prepare NiCr-Cr3C2-hBN@Ni coating are investigated in this study using finite element simulation. As a result, the deformation and stress of thin-walled workpieces can be minimized by adding back-side cooling air during the spraying process and moving the cooling air with the gun in a set interval, with the maximum warpage and maximum stress being less than 2.366 mm and 0.177 GPa, respectively. During the spraying process by simulating the optimum spraying process, no significant warpage of the substrate occurred and the coating was sprayed with uniform thickness. Typically, the thickness error rate is 16.7 %, and the coating hardness reaches 15–20 GPa, with excellent tribological properties in a wear rate of 10−5 mm3·N−1·m−1 and 10−6 mm3·N−1·m−1, which protects the workpiece effectively.

Precipitation mechanism of abrasive particles in magnetorheological polishing fluid and experimental verification

This study aims to address the issue of poor workpiece surface machining quality due to inadequate abrasive particle precipitation during the processing of magnetorheological polishing fluid. The paper employs magnetic dipole theory and molecular dynamics theory to establish a microdynamics model for magnetorheological polishing fluid and conducts kinematic and dynamic analyses of magnetic and abrasive particles. The chaining process of magnetic particles in magnetorheological polishing fluid was simulated under an external magnetic field, and the precipitation process of abrasive particles under the action of magnetic particles was simulated and analyzed. Furthermore, we established a microscopic observation experimental platform for magnetorheological polishing fluid and verified the precipitation law of abrasive particles under the action of dynamic magnetic field. The study findings indicate that the magnetic particles will form a chain structure, when the rotating magnetic field has an effect on the magnetorheological polishing fluid, and the abrasive particles will precipitate from the magnetorheological polishing fluid and adhere to the upper end of the magnetic chain. Moreover, the precipitation rate of abrasive particles is also affected by the magnetic field strength, the volume fraction of magnetic particles, and the rotating magnetic field speed, with the abrasive particles’ precipitation rate specifically increasing with higher magnetic field strength. At a magnetic field strength of 100 kA/m, the abrasive precipitation rate reaches 80 % in approximately 90 s, which increases to 80 % in only 60 s at a magnetic field strength of 200 kA/m. Additionally, with the increase of magnetic particle volume fraction, the precipitation rate of abrasive particles decreases. Within the first 40 s of the test, the magnetic particle volume fraction increases from 10 % to 30 %, and the precipitation rate of abrasive particles decreases by about 11 %. Similarly, the abrasive precipitation rate is affected differently by the rotating magnetic field speed. As the rotating magnetic field speed increases, the abrasive precipitation rate shows a trend of first increasing and then decreasing. When the rotating magnetic field speed increases from 20 r/min to 40 r/min, the abrasive precipitation rate of the first 40 s increases by about 25 %. When the speed continues to increase to 60 r/min, the precipitation rate of abrasive particles gradually decreases.

Modelling of polyurethane polishing pad surface topography and fixed-point polished surface profile

Polishing process, is an important process of ensuring surface quality and precision. However, it is difficult to achieve quantitative material removal and polish to target surface profile accurately, due to the special structure characteristic of polishing pad and the complex contact mechanism between polishing pad-abrasive particle-workpiece surface. Therefore, this study proposes a statistic model for polyurethane polishing pad surface, which take into consideration of the circular hole size (Gaussian distribution), density and location distribution (random distribution) on polishing pad surface. On the basis of the polishing pad surface model, this study further establishes a predicting model for polishing surface profile through analyzing of the effective number of abrasive particles between polishing pad and workpiece, the real contact force between a single abrasive particle and workpiece surface, the single abrasive particle footprint, the overlapping and superimposing of abrasive particle footprint. A series of polishing pad comparative analysis and SiC polishing experiments with different parameters are performed. Both of the two models are validated through qualitative and quantitative comparisons of simulation and experiment results. The proposed models not only lay the foundation for an in-depth understanding of the material removal mechanism in polishing process with polyurethane polishing pads, but also meaningful to other polishing process with polyurethane polishing pads and the optimization of polishing process.

A symmetric spiral arc with variable diameter path generation method for achieving uniform surface roughening processing

Uniform surface roughening processing can increase the surface area and thus improve the mechanical interlocking strength. This paper presents a method for generating a symmetric spiral arc with variable diameter path to achieve uniform surface roughening. By constructing a material removal model for the surface roughening process, the contact area radius and maximum removal depth are determined under specific process parameters. A path generation algorithm is designed on a plane to generate paths while ensuring that the maximum removal depth does not breakthrough and damage the surface layer and guaranteeing uniform coverage of the contact area. The planar paths are scaled before projection to achieve equidistant projections of adjacent paths on the spherical surface. The modified paths are then projected onto the surface of the spherical workpiece using inverse spherical pole projection. Moreover, a comparative experiment is conducted between the traditional path and the proposed path to validate the effectiveness and the uniform coverage achieved. The changes in surface roughness before and after processing are evaluated by comparing the treated surfaces with the untreated surfaces. The experimental results indicate that using the symmetric spiral arc with variable diameter path for surface roughening yields better uniform coverage. The increase in surface roughness before and after processing confirms the ability of the proposed path to achieve surface roughening.

Effect of Viscoelastic Characteristics on the Real Contact Area of Polishing Pad Surface

Real contact area (RCA) between polishing pad and workpiece surface is one of the most important parameters indicating the mechanical action strength of chemical mechanical polishing (CMP), which has a dominated effect on the material removal. However, the effect of pad viscoelastic characteristics on RCA is not clear. In this study, a contact status measurement device that can apply cyclic load and record contact images is developed to study the viscoelastic behavior of the pad and its influence on RCA. The results show that when the pad undergoes cyclic compression load during CMP, the pad asperity layer gradually accumulates viscoelastic deformation and the RCA increases obviously, which can be mostly recovered after a long time. In particular, the accumulation and recovery of viscoelastic deformation lead to a significant change of the relationship between RCA and pressure, from linear to nonlinear and then to linear. Furthermore, an RCA model is established based on the viscoelastic constitutive model of pad and the mathematical relationship between RCA and pad deformation to explain the influence of pad viscoelastic behavior on RCA. This study is expected to provide new insights into RCA, and to give support for predictive control of the material removal during CMP.

Multi-axis CNC finishing and surface roughness prediction of TC11 titanium alloy open integral micro impeller

The titanium alloy open integral micro impeller has a strong material strength and high removal rate in the field of multi-axis CNC machining. The flow channel is tiny and the blades are thin and highly twisted. It is difficult to control the surface accuracy and prone to overcutting and undercutting. The NX2212 software post-processing module plans two distinct blade finishing process routes and verifies them using virtual machine tool simulation, taking into account the technical challenges of micro impeller machining. Following verification, the tool path machining code is imported into MATLAB for data fitting. The workpiece surface working condition is determined based on the simulation findings, the blade surface roughness value is calculated, and a physical simulation model of blade finishing is created in the finite element analysis software. The outcomes demonstrate how well the “segmented and sub-regional cutting” processing method may raise blade accuracy. The leading and trailing edges of the blade both had surface roughness increases of 4.86% and 4.19%. The surface morphology of the micro impeller is measured using a white light interferometer, and it is CNC machined using two distinct process methods. The findings demonstrate that there is a significant difference between the value calculated by the finite element analysis software and the surface roughness value measured experimentally which together make up less than 5%. An investigation of the impact of cutting parameters on the surface roughness of micro-structure components is carried out using a three factor, three-level BBD experiment that is founded on the second-order response surface method. The findings indicate that the feed per tooth influences surface roughness more significantly than cutting depth and cutting speed for a reasonable range of cutting parameters; Surface roughness will rise with lower or higher cutting speeds; Raising the feed per tooth and the cutting speed simultaneously may reduce surface roughness; Surface roughness can be accurately predicted and controlled using the second-order response surface method.

Electric field simulation in the electrochemical machining of a thin-walled part cavity

The article is aimed at simulating an electric field in the interelectrode gap during the electrochemical machining of a thin-walled part cavity for aerospace equipment. The study involved simulating the process of electrochemical cavity machining at a constant voltage in a steady-state mode in the COMSOL Multiphysics environment. The simulation was carried out for the scheme of electrochemical machining with a movable cathode and vertical and horizontal feeding to the workpiece surface undergoing machining while maintaining a constant interelectrode gap. The following simulation conditions were adopted: 12Cr18Ni10Ti stainless steel as the material of the cathode tube; AlMg6 aluminum alloy as the material of the thin-walled part; NaNO3 solution as the electrolyte. When simulating the electric field in the interelectrode gap, the heat exchange process was taken into account. The simulation of the electric field in the electrochemical cavity machining of a thin-walled part yielded a macro that allows the process simulation to be adapted to different input process conditions. As a result of the simulation, the following distribution patterns were obtained: current density in the cathode, potentials, electric field in the interelectrode gap and adjacent area, and process temperature of electrochemical machining. The simulation results show that the electric field lines are directed toward the cathode from the workpiece periphery. This means that anodic dissolution of material occurs in a given region, which characterizes the law concerning the distribution of potentials in an electrochemical cell. The temperature distribution pattern obtained in the simulation revealed that a temperature increase in the machining zone is insignificant. An increase in electrolyte temperature is shown to result in a proportional increase in wall temperature. Thus, the conducted study provides a theoretical insight into the examined process.

Modelling and Optimization of Machined Surface Topography in Ball-End Milling Process.

In order to optimize machined surface topography, this paper presents a novel algorithm for simulating the surface topography and predicting the surface roughness of a ball-end milling process. First, a discrete workpiece model was developed using the Z-map method, and the swept surface of a cutter edge was represented using triangular approximation. The workpiece surface was updated (i.e., material removal process) using the intersection between the vertical reference line and the triangular facet under a cutting judgement. Second, the proposed algorithm was verified by comparing the simulated 3D surface topography as well as 2D surface profile and average roughness (Sa) with experimental measurements. Then, numerical simulation examples planed by the Box-Behnken design methods were carried out to investigate the Sa in the ball-end milling operation. The correlations of Sa and cutting parameters were represented by a response surface reduced quadratic model based on the ANOVA results. Finally, the feed per tooth, radial depth of cut, and tilt and lead angles were optimized for improving the machining efficiency under the Sa constraints. This study presents an effective method for simulating surface topography and predicting the Sa to optimize the cutting parameters during ball-end milling process.

Effects of dealloying surface modification on machinability improvement of NiTi alloy during micro-machining process

In this work, a novel dealloying assisted machining (DAM) method is proposed to modify the machinability of a typical high toughness NiTi alloy. The DAM method can produce nanoporous layer on workpiece surface through dealloying process. Under different cutting depths, micro-milling experiments are performed on workpieces with and without dealloying surface modification. The results indicate that the embrittlement effect of nanoporous layer induce ductile to brittle transition during material removal process leading to the fragmented chip formation. Consequently, the cutting force and temperature decrease by over 14% and 12%, respectively. Meanwhile, the tool wear is alleviated and the machined surface quality is improved. The proposed method can also provide guidance for micro machining of other difficult-to-machine materials.

Error Analysis of Normal Surface Measurements Based on Multiple Laser Displacement Sensors.

The robotic drilling of assembly holes is a crucial process in aerospace manufacturing, in which measuring the normal of the workpiece surface is a key step to guide the robot to the correct pose and guarantee the perpendicularity of the hole axis. Multiple laser displacement sensors can be used to satisfy the portable and in-site measurement requirements, but there is still a lack of accurate analysis and layout design. In this paper, a simplified parametric method is proposed for multi-sensor normal measurement devices with a symmetrical layout, using three parameters: the sensor number, the laser beam slant angle, and the laser spot distribution radius. A normal measurement error distribution simulation method considering the random sensor errors is proposed. The measurement error distribution laws at different sensor numbers, the laser beam slant angle, and the laser spot distribution radius are revealed as a pyramid-like region. The influential factors on normal measurement accuracy, such as sensor accuracy, quantity and installation position, are analyzed by a simulation and verified experimentally on a five-axis precision machine tool. The results show that increasing the laser beam slant angle and laser spot distribution radius significantly reduces the normal measurement errors. With the laser beam slant angle ≥15° and the laser spot distribution radius ≥19 mm, the normal measurement error falls below 0.05°, ensuring normal accuracy in robotic drilling.

Temperature field simulation and optimization of processing parameters for laser-assisted machining of 3Y-TZP ceramics

To obtain low surface roughness in the laser-assisted machining of 3Y-TZP ceramics, a laser-assisted heating model of 3Y-TZP ceramics was established. The temperature field in the cutting zone was simulated using ABAQUS software to analyze the effects of laser power, rotational speed, and warm-up time on softening layer depth (distance between the workpiece surface and lower boundary of softening layer) and thickness (distance between the upper and lower boundaries of softening layer). Furthermore, the accuracy of the simulation results was verified through experiments. The Plackett-Burman design, Steepest ascent experiment, and Box-Behnken design method were used sequentially to optimize process parameters, and the surface quality, chip morphology, and tool wear of 3Y-TZP ceramic with laser-assisted cutting and traditional cutting were compared under the best process parameters. The results show that the rotational speed and laser power are the main factors influencing the softening layer depth and thickness, and the suitable warm-up time is 15 s; the most influential factor on the surface roughness is the cutting depth, and the optimized process parameter combinations for the best surface roughness are as follows: laser power of 90.3 W, rotational speed of 400 r/min, cutting depth of 0.21 mm, and feed speed of 4.4 mm/min; with laser-assisted, the surface roughness value of the workpiece is reduced by 54.12 %, the amount of tool wear is reduced by 56.5 %, the chip morphology is transformed from powder to strip with a length of more than 50 μm, and the primary material removal mode is changed from brittle removal to plastic removal.

The Development of the Stress-Free Polishing System Based on the Positioning Error Analysis for the Deterministic Polishing of Jet Electrochemical Machining.

Deterministic polishing based on jet electrochemical machining (Jet-ECM) is a stress-free machining method for low-rigidity and ultra-precision workpieces. The nozzle is equivalent to a special tool in deterministic polishing, and the workpiece material is removed using the mechanism of electrochemical dissolution at the position where the nozzle passes. By precisely regulating the nozzle's movement speed and dwell time, the quantity of material removed from the workpiece at a designated position can be finely adjusted. With this mechanism, the improvement of the workpiece shape accuracy can be achieved by planning the nozzle trajectory and nozzle movement speed. However, due to the positioning errors of the polishing device, the actual position of the nozzle may deviate from the theoretical position, resulting in errors in material removal amount, which affects the accuracy and stability of the polishing process. This study established a mathematical model to analyze the influence of nozzle positioning errors in deterministic polishing based on Jet-ECM. This model has been used to design a specific deterministic polishing device based on Jet-ECM. With the proposed deterministic polishing device, the surface shape of the workpiece is converged. The surface peak-to-valley (PV) value of the φ 50 mm workpiece (valid dimensions = 90% of the central region) indicated that the shape error of the surface was reduced from 2.67 μm to 1.24 μm in 34 min. The power spectral density (PSD) method was used to evaluate the height distribution and height characteristics of the workpiece surface. The results show that the low frequency spatial error is reduced significantly after processing. This study improves the accuracy of the stress-free deterministic polishing methods and further expands the use of deterministic polishing in industry.

Modeling and control of electrical discharge wire sawing of single-crystal silicon

Electrical discharge wire sawing (EDWS) is a new composite processing method that combines wire electrical discharge machining with fixed abrasive wire sawing. During processing, relying on the grinding effect of the abrasive grains, craters and recast layers generated by discharge are removed. The surface roughness of the workpiece is reduced while the cutting efficiency is improved. In this study, the relationship between discharge voltage and workpiece surface roughness in composite machining is investigated. A single-input single-output control system model with applied resistance as the input and discharge voltage as the output is established. Based on the theory of system identification and parameter estimation, the order of the model is identified by calculating the variance of the model residuals and using the F-test method. The model parameters of the control system are estimated online using a recursive least squares algorithm with a forgetting factor. A generalized predictive controller is designed on the basis of the predictive control theory and the identified discharge voltage control system model. Using LabVIEW software, a discharge voltage prediction control system is constructed for the processing of single-crystal silicon by EDWS, and its prediction control performance is experimentally verified. The results show that the discharge voltage control system designed in this study can successfully control the composite machining of single-crystal silicon in real time. Under the same machining conditions, the surface roughness of the workpiece machined with predictive control was 23.5 % lower than that without predictive control.

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.