Magnetorheological Finishing Technology: Research Progress in Materials, Mechanisms, Equipment, and...

Magnetorheological Finishing (MRF) technology, as a deterministic machining method featuring flexibility, controllability, and extremely low subsurface damage, has become one of the most promising technologies in the field of ultra-precision polishing. This review systematically summarizes the research progress of MRF technology in aspects such as polishing fluid preparation and rheological properties, material removal mechanisms and theoretical models, classification and optimization of equipment and processes, multi-energy field hybrid technologies, and intelligent development. First, starting from the composition, nonlinear rheological models, and stability optimization of the magnetorheological polishing fluid, the decisive influence of fluid properties on finishing performance is elucidated. Second, the macroscopic mechanical removal mechanism and the atomic-scale material removal mechanism are analyzed, and the establishment and development of material removal function and polishing force models are reviewed. Third, MRF equipment is systematically classified according to tool morphology, and advanced hybrid polishing technologies such as ultrasonic-assisted, electrochemical-assisted, and laser-assisted methods are discussed. Furthermore, the effects of key process parameters, magnetic field configuration optimization, and dwell time algorithms on machining accuracy and efficiency are analyzed in depth. Finally, typical applications of MRF technology in aerospace, biomedical, optoelectronic information and other fields are summarized, the current technical bottlenecks are pointed out, and future development trends toward intelligence, greenization, and standardization are prospected. This review aims to provide comprehensive theoretical references and technical guidance for researchers in the MRF field, and to promote further application and development of this technology in precision manufacturing.