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The freeform complex surfaces have become an inevitable part of many components to perform specific functions. Many of these components require nanometer surface roughness to meet specific requirements in their application domain. Therefore, finishing operation as a final operation is necessary for such components. A magnetorheological fluid-based finishing tool is developed for finishing knee joint implant, which has complex freeform surfaces. Different types of magnetorheological fluids and various finishing steps are proposed to reduce finishing time. Surface characteristics of the knee joint implant are studied using a surface roughness measuring instrument and atomic force microscopy before and after finishing. A significant reduction in surface roughness (the best final surface roughness value obtained = 28 nm) is observed on the component after finishing. The surface roughness obtained on different surfaces is well within the values recommended in the ASTM standard for total knee joint prosthesis.

The quality of surface is one of the significant parameters which affects the life and functionality of any product. Many products require nano-level surface finish as their functional indispensability. Those processes having flexible finishing tool can be employed for such type of components. These finishing processes can be classified into two categories: with and without magnetic field assistance. The former includes magnetic abrasive finishing, magnetorheological finishing, and allied processes, and the latter includes abrasive flow finishing. This article reports the critical review of mainly three processes: abrasive flow finishing, magnetorheological finishing, and magnetorheological abrasive flow finishing. In this article, the issues that need attention of the researchers have been categorically mentioned. This article provides a comprehensive literature review of magnetorheological finishing process in terms of rheological characterization of magnetorheological fluid, experimental investigation, theoretical analysis, and applications. This article deals with various advancements in abrasive flow finishing and hybrid processes. The developments in magnetorheological abrasive flow finishing and its allied processes have been discussed in detail. By suitable modification of magnetorheological abrasive flow finishing process, it can achieve surface finish up to nano-meter on different materials such as brass, aluminium, stainless steel, and silicon-nitride.

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