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ABSTRACT
Various plastic products such as bottles’ plastic caps are manufactured through casting using permanent molds. To obtain the smooth surface on plastic caps during manufacturing, the required permanent mold die punch surface should be defect free and its roughness values in nanometer range. Two different magnetorheological (MR) fluid-based finishing processes are used for nano-surface-finishing of die punch. The MR ball end with solid rotating tool core is used to finish the flat surface, and a turning type MR finishing process is used for external circular surface of the present mold die punch. The material of the present permanent mold punch is P20 tool steel with hardness of 431 VHN. The final roughness values of flat and external circular surfaces of the present die punch are obtained as 30 nm and 80 nm from the initial values of 1080 nm and 630 nm in 120 min of finishing. The change in topography of the surface is observed using metallurgical microscope and mirror image test. The reduction in surface roughness at the nanolevel and microscopic improvement on the die punch surface have demonstrated the feasibility of present finishing processes to be useful in industries for manufacturing the smooth surface of bottles’ plastic caps.