Amirkabir University of Technology Amirkabir Journal of Mechanical Engineering 2008-6032 57 4 2025 06 22 Synergistic Effect of Rotating Magnetic Field and Ultrasonic Vibrations in Magnetorheological Abrasive Flow Finishing Synergistic Effect of Rotating Magnetic Field and Ultrasonic Vibrations in Magnetorheological Abrasive Flow Finishing 453 472 5822 10.22060/mej.2025.24373.7862 FA Yahya Choopani Department of Mechanical Engineering, Meybod University, Meybod, Iran Mohsen Khajehzadeh Mechanical Engineering Department, Amirkabir University of Technology, Tehran, Iran Mohammad Reza Razfar Mechanical Engineering Department, Amirkabir University of Technology, Tehran, Iran Journal Article 2025 07 09 This study employed rotating magnetic fields and ultrasonic vibrations as an effective solution to overcome the limitations associated with the magnetorheological abrasive flow finishing (MRAFF) process. To this end, first, an industrial prototype of the MRAFF setup was designed and fabricated. After preparing the magnetorheological polishing (MRP) fluid, a rotating magnetic field was applied, and subsequently, ultrasonic vibrations were applied to the workpiece in a direction perpendicular to the fluid flow. In order to evaluate the efficiency of the proposed technique, the effect of processing time on three indices, i.e., surface roughness rate, finishing rate, and material removal rate, in aluminum alloy 2024 tubes was investigated. The results indicated that during the first 10 minutes of processing, besides a decrease observed in the surface roughness ratio, the finishing rate and material removal rate also increased; however, due to the destructive effects of abrasive particles, the continuation of the process caused a re-increase in the surface roughness. Microscopic images not only confirmed these findings but also indicated that under optimal conditions, in addition to creating a uniform surface, the proposed technique reduced the roughness of the inner surface of the tubes by 98%. As a result, this method offers a promising prospect as an efficient solution for finishing and deburring inner surfaces, especially in longer tubes. This study employed rotating magnetic fields and ultrasonic vibrations as an effective solution to overcome the limitations associated with the magnetorheological abrasive flow finishing (MRAFF) process. To this end, first, an industrial prototype of the MRAFF setup was designed and fabricated. After preparing the magnetorheological polishing (MRP) fluid, a rotating magnetic field was applied, and subsequently, ultrasonic vibrations were applied to the workpiece in a direction perpendicular to the fluid flow. In order to evaluate the efficiency of the proposed technique, the effect of processing time on three indices, i.e., surface roughness rate, finishing rate, and material removal rate, in aluminum alloy 2024 tubes was investigated. The results indicated that during the first 10 minutes of processing, besides a decrease observed in the surface roughness ratio, the finishing rate and material removal rate also increased; however, due to the destructive effects of abrasive particles, the continuation of the process caused a re-increase in the surface roughness. Microscopic images not only confirmed these findings but also indicated that under optimal conditions, in addition to creating a uniform surface, the proposed technique reduced the roughness of the inner surface of the tubes by 98%. As a result, this method offers a promising prospect as an efficient solution for finishing and deburring inner surfaces, especially in longer tubes. https://mej.aut.ac.ir/article_5822_fd2ae8ec902471d8956fca3486031013.pdf