This study explores the application of a magnetorheological (MR) finishing method to enhance thread roller surface quality while improving overall performance. Thread rollers used in threading operations exhibit surface defects, which ultimately lead to degradation and reduced endurance over time. This research seeks to advance the capabilities of these rollers which originally have HV 694 hardness before undergoing MR treatment. The implementation of MR finishing technology increases HV 746 hardness measurements, which lead to enhanced operational smoothness and contributes to longer roller lifetime expectations. A single electromagnetic-based MR finishing setup featuring interchangeable tool cores performs external thread profile fine finishing operations in this research. Surface finish optimization is achieved using response surface methodology to identify critical process parameters. Surface roughness tests show an improvement from an initial value of 0.27 μm to 0.02 μm bringing about significant enhancement in surface features. Tests evaluating microhardness help determine the effectiveness of the process. The MR finishing technique distributes pressure more evenly across rol
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