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<p>The automotive aerospace and medical industries rely heavily on precision manufacturing using 3D-printed mold punches that resulted from the swift development of advanced additive manufacturing (AM) technologies. The basic traits of 3D-printed components deteriorate functional performance because their surface displays inherent roughness caused by layering processes and geometric faults. 3D-printed mold punches show numerous drawbacks when faced with the technical difficulties that stem from their complex structural features and varied material properties during traditional finishing operations. Researchers conduct thorough studies to demonstrate how magnetorheological finishing stands as a new surface finishing method designed to upgrade metal alloy-based 3D-printed mold punches. This research analyzes magnetorheological finishing (MRF) technology by studying how it reshapes additively made parts regarding their surface texture and microscopic structure while enhancing their tribological features. Experimental experiments with MRF technology led to exceptional surface roughness improvement where 0.55&#xa0;μm transformed into 0.03&#xa0;μm and yielded a surface quality enhancement of 94.5%. The research showed that MRF could remove layer-induced surface artifacts completely and simultaneously increase microhardness by 20% while cutting coefficient of friction by 35% on untreated 3D-printed specimens. The analysis based on advanced SEM and profilometry validated how the controlled MRF process delivered uniform material reduction along with excellent surface uniformity. MRF functions as a surface finishing technology which revolutionizes 3D-printed mold punch performance and precision in advanced manufacturing environments.</p>

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Precision Surface Finishing of Additively Manufactured ABS Punches via Magnetorheological Finishing

  • 期刊论文

  • 发表日期：

    2025年11月10日

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  • Manpreet Singh,
  • Gagandeep Singh

摘要

The automotive aerospace and medical industries rely heavily on precision manufacturing using 3D-printed mold punches that resulted from the swift development of advanced additive manufacturing (AM) technologies. The basic traits of 3D-printed components deteriorate functional performance because their surface displays inherent roughness caused by layering processes and geometric faults. 3D-printed mold punches show numerous drawbacks when faced with the technical difficulties that stem from their complex structural features and varied material properties during traditional finishing operations. Researchers conduct thorough studies to demonstrate how magnetorheological finishing stands as a new surface finishing method designed to upgrade metal alloy-based 3D-printed mold punches. This research analyzes magnetorheological finishing (MRF) technology by studying how it reshapes additively made parts regarding their surface texture and microscopic structure while enhancing their tribological features. Experimental experiments with MRF technology led to exceptional surface roughness improvement where 0.55 μm transformed into 0.03 μm and yielded a surface quality enhancement of 94.5%. The research showed that MRF could remove layer-induced surface artifacts completely and simultaneously increase microhardness by 20% while cutting coefficient of friction by 35% on untreated 3D-printed specimens. The analysis based on advanced SEM and profilometry validated how the controlled MRF process delivered uniform material reduction along with excellent surface uniformity. MRF functions as a surface finishing technology which revolutionizes 3D-printed mold punch performance and precision in advanced manufacturing environments.