Particle collision-based abrasive flow mechanisms in precision machining
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ORIGINAL ARTICLE
Particle collision-based abrasive flow mechanisms in precision machining Junye Li 1 & Zhibao Zhu 1 & Jinglei Hu 1 & Zengwei Zhou 1 & Xinming Zhang 1 & Weihong Zhao 1 Received: 7 December 2019 / Accepted: 17 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Although abrasive flow technology is a non-conventional approach to finishing in precision machining, it offers particular advantages when machining micro-hole workpieces. This paper combines theoretical, numerical, and experimental methods to study the use of abrasive flow technology in this way. The nature of the collision of abrasive particles with a workpiece is analyzed to reveal the exact mechanisms involved in removing material using an abrasive flow. The experimental results show the importance of the plowing effect of the abrasive grains on the surface of the workpiece. The results are discussed in relation to the surface morphology of the workpiece before and after the application of the abrasive flow. After abrasive flow machining the surface roughness values were greatly reduced, achieving measures of between 0.418 and 0.285 μm in some areas. It is concluded that abrasive flow technology holds great promise for the production of high-quality workpiece surfaces in precision engineering. The results of this research offer particular insights for the further development of abrasive flow technology. Keywords Abrasive flow machining . Particle collision . Processing quality . Friction and wear mechanism
1 Introduction Abrasive flow precision machining is a novel technology that uses an abrasive flow polishing fluid containing extremely hard abrasive grains to improve the surface finish of a workpiece. Precision processing technology that uses abrasive flow is known to offer particular advantages over other polishing methods, including high processing efficiency, good uniformity, and minimal damage to lower surfaces [1–5]. As a result, this non-traditional approach has begun to attract global attention. At the same time, the technology is continually being improved and the process parameters have been increasingly refined. Li et al. [6, 7] used dynamic molecular simulations to study the abrasive flow polishing mechanism at a microscopic scale and concluded that analysis of different cutting depths and wear properties of different workpiece materials would improve understanding of the effects of the approach. Having also analyzed the impact of different * Xinming Zhang [email protected] 1
Ministry of Education Key Laboratory for Cross-Scale Micro and Nano Manufacturing, Changchun University of Science and Technology, Changchun 130022, China
directions of abrasive flow during the polishing process, we found that a small cutting angle is beneficial for improving surface quality and reduces the number of internal defects. Soft abrasive flow has been found to have some inherent efficiency problems. Li et al. [8] therefore sought to solve these issues by constructing a flow channel with a zigzag cross section. Th
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