Fine finishing of the variable diametric external surface of the tapered cylindrical components is the utmost need of the advanced manufacturing industries. The tapered colored glass-making industries require the highly finished taper cylindrical punches and cavities. To achieve this requirement, the magnetorheological (MR) finishing process is utilized through its advancement for enhancing the surface characteristics of the tapered cylindrical punch workpieces. In the present work, to realize the MR finishing mechanism on the tapered cylindrical punch workpiece, the final average surface roughness was analyzed theoretically. In addition, the variation in linear velocity, helix angle, and the helical path made by the active abrasive on the tapered cylindrical surface was also analyzed for the time required to perform uniform precise finishing on the variable surface of the tapered cylindrical workpiece. After the magnetorheological finishing, the significant improvement in the surface characteristics of the tapered cylindrical workpiece was accomplished. Also, the surface roughness parameters (Ra, Rq, and Rz) values got reduced by 97.28 %, 95.82 %, and 95.42 % with the optimized parametric conditions. The corresponding surface waviness value also got reduced from the initial value of 0.8410 μm to the final value of 0.2057 μm. The significant improvement in the surface characteristics of the tapered cylindrical workpiece after the MR finishing can be found beneficial for improving its functional life. This further helps in achieving the accurate dimensions with defect-free end products as produced by using the MR finished tapered cylindrical punches in the manufacturing industries.

锥形圆柱组件的可变直径外表面的精加工是先进制造业的最高需求。锥形彩色玻璃制造行业需要高度精加工的锥形圆柱冲头和型腔。为了达到这一要求，磁流变（MR）精加工工艺通过其进步来增强锥形圆柱冲头工件的表面特性。在目前的工作中，为了实现对锥形圆柱冲头工件的MR精加工机制，理论上分析了最终的平均表面粗糙度。另外，线速度，螺旋角，并分析了活性磨料在锥形圆柱表面上形成的螺旋路径，以确定在锥形圆柱工件的可变表面上进行均匀精确精加工所需的时间。磁流变抛光后，锥形圆柱工件的表面特性得到了显着改善。另外，表面粗糙度参数（在优化的参数条件下，Ra，Rq和Rz）值分别降低了97.28％，95.82％和95.42％。相应的表面波纹度值也从初始值0.8410μm降低到最终值0.2057μm。可以发现，在MR精加工之后，锥形圆柱工件的表面特性有了显着改善，这有助于延长其功能寿命。通过在制造行业中使用MR精加工的锥形圆柱冲头生产的无缺陷最终产品，这进一步有助于实现准确的尺寸。