Deterministic magnetorheological finishing

A method of finishing a workpiece surface using magnetorheological fluid, comprising:

• (a) positioning the workpiece near a continuous carrier surface such that a converging gap is defined between a portion of the workpiece surface and the carrier surface, wherein said carrier surface extends along a rim of a vertically oriented wheel;
• (b) applying a magnetic field substantially at said gap;
• (c) depositing magnetorheological fluid from a magnetorheological fluid source on the carrier surface;
• (d) moving the carrier surface past said workpiece by rotating the wheel such that magnetic field-stiffened magnetorheological fluid flows through said converging gap defining a work zone forming a transient finishing tool for engaging and causing material removal at a portion of the workpiece surface;
• (e) moving the workpiece or the work zone relative to the other to expose different portions of the workpiece surface to the work zone for predetermined time periods to selectively finish said portions of said workpiece surface to predetermined degrees;
• (f) collecting magnetorheological fluid that has flowed through said gap from said carrier surface;
• and
• (g) returning the magnetorheological fluid collected in step (f) to the magnetorheological fluid source.