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The requirement of finishing tungsten carbide at the nano level has drastically increased due to recent development in the field of punch and dies manufacturing industry. The surface roughness has a considerable impact on the quality of the created product. The current study’s major purpose is to investigate how well tungsten carbide can be completed using the solid rotating core magnetorheological finishing (MRF) method. Response surface approach is used to screen studies in order to find the main parameters impacting tungsten carbide surface roughness. The concentration of diamond abrasives, the current induced in the electromagnetic coil, the gap maintained between the workpiece surface, the solid rotating tool core tip surface, and the tool’s rotational speed are the process parameters used in this work. The process parameters in the magnetorheological finishing of tungsten carbide have a significant influence in lowering the considerable value of surface roughness. The minimal surface roughness value found on the tungsten carbide workpiece after 45 min of finishing by the solid rotating core magnetorheological finishing method was as low as 54 nm, down from an initial value of 248 nm. To analyze the finished surface characteristics of the tungsten carbide, the study of surface morphology test is performed. After performing the present MRF, the surface characteristics of the tungsten carbide show a substantial improvement. Thus, the fine finishing with the improved smooth surface quality of the tungsten carbide workpiece may improve its performance in the mold and dies manufacturing industry.

The need for finishing chrome steel punch has drastically increased in order to obtain products with high quality and productivity. Chrome steel finds its application in manufacturing of punch and dies because of its higher hardness as varies up to 62 HRC. The paper is focused on improving the productivity of chrome steel punch through improving the surface finish using magnetorheological finishing process with a solid rotating tool core. The traditional method used for finishing of the chrome steel punch involves diamond lapping where machining marks and surface micro cracks are observed. In punching operation, the punch undergoes adhesive wear which can be controlled if the surface finish of the punch is improved. The surface finish obtained after diamond lapping process is up to 408 nm range. In present work, the further finishing of the tapered cavity of chrome steel punch is carried out. The chrome steel punch workpiece is rotated in a direction opposite to the rotation of the tapered tool tip surface in order to efficiently perform the finishing operation. The final surface roughness value of the flat surface of circular tapered punch is obtained as 26 nm from 420nm while the roughness value of the tapered surface is obtained as 22 nm from 408 nm in 90 minutes of finishing.