Future perspectives and research trends in advanced chemo-mechanical magneto-rheological finishing for enhanced surface quality

The increasing demand for precision manufacturing and surface finishing has prompted the development of innovative techniques to achieve superior results. Surface quality is considered a crucial characteristic that impacts the lifespan and functionality of any product. Due to their essential functionality, many products necessitate a surface finish at the nano-level. Chemo-mechanical magneto-rheological finishing (CMMRF) is a leading surface finishing technique that controls finishing in various materials with less time. Considering the demand for precise and high-quality metal outcomes in numerous industries, including electronic and laser optics parts, it is crucial to consider future perspectives and research developments in CMMRF since the result of the surface finish (Ra) that the CMMRF attained on some metals was 0.5 nm. This review comprehensively analyzes recent research on the CMMRF process. Also, it discusses the process mechanism of CMMRF, referring to the recent advancements in magneto-rheological (MR) finishing that have led to the development of composite magnetic abrasives (CMA), which enhance (Ra) and material removal rates compared to conventional sintering magnetic abrasives (SMA). Moreover, it showcases how process parameters affect the final Ra, signifying the time needed to complete and resulting in a significantly lower Ra value; the most minor Ra reported was 8.4 nm in 50 min. The study explores current research trends and potential improvements in surface integrity, highlighting the CMMRF procedure as a significant innovation for precision surface finishing.