Influence of magnetorheological finishing on roller surface properties and thread rolling efficiency

This study explores the application of a magnetorheological (MR) finishing method to enhance thread roller surface quality while improving overall performance. Thread rollers used in threading operations exhibit surface defects, which ultimately lead to degradation and reduced endurance over time. This research seeks to advance the capabilities of these rollers which originally have HV 694 hardness before undergoing MR treatment. The implementation of MR finishing technology increases HV 746 hardness measurements, which lead to enhanced operational smoothness and contributes to longer roller lifetime expectations. A single electromagnetic-based MR finishing setup featuring interchangeable tool cores performs external thread profile fine finishing operations in this research. Surface finish optimization is achieved using response surface methodology to identify critical process parameters. Surface roughness tests show an improvement from an initial value of 0.27 μm to 0.02 μm bringing about significant enhancement in surface features. Tests evaluating microhardness help determine the effectiveness of the process. The MR finishing technique distributes pressure more evenly across roller surfaces to decrease materials’ wear properties and enhance operational efficiency. Experimental studies combined with theoretical investigations evaluate key parameters to measure roller force torque and power consumption while assessing the impact of MR finishing treatments on device performance. The research consistently demonstrates that roller surfaces treated with MR-finishes demonstrate enhanced performance in practically all metrics. Surface quality improvements through MR finishing treatments lead to efficient roller operation along with extended service lives in commercial thread applications.