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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.
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