Magnetorheological shear thickening polishing (MRSTP) demonstrates significant potential for the precision processing of titanium alloys. However, prior studies have primarily focused on surface roughness, while comprehensive experimental investigations remain limited. Moreover, the underlying mechanisms have yet to be explored. To address these research gaps, comprehensive MRSTP experiments are conducted on Ti-6Al-4V using a multi-pole coupling magnetic field, considering surface roughness, polishing force, and material removal rate. The optimal parameters are determined, including a carrier fluid concentration of 20 wt%, an abrasive concentration of 7.5 wt%, an abrasive size of 13 μm, a carbonyl iron particle size of 50 μm, a magnetic flux density of 140 mT, a feed rate of 6000 mm/min, and a spindle speed of 100 r/min. After 60 min of MRSTP under these conditions, the surface roughness is reduced from approximately 280 to 24 nm, achieving a mirror-like appearance. The normal and tangential forces are measured to be 4.04 and 1.74 N, respectively, with a corresponding material removal rate of 24.3 mg/h. The formation of enhanced particle clusters explains the underlying mechanisms for these variations. This study provides valuable insights into tailoring MRSTP strategies for specific difficult-to-machine materials and into understanding the MRSTP mechanism. 1 | Introduction Titanium alloys, particularly Ti-6Al-4V, have attracted significant attention in advanced ma
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