Material Removal Mathematics Model of Shear Thickening Polishing

doi:10.3901/JME.2016.07.142

Abstract

Abstract: Based on the non-Newtonian power-law fluid with shear thickening mechanism, shear thickening polishing (STP) as a novel ultra-precision machining method is proposed. The minimum thickness between non-Newtonian fluid of shear thickening polishing and workpiece is deduced through the study on the theory of shear elastic layer. According to Preston equation, the material removal mathematics model is deduced and founded. At constant velocity of flow (U), non-Newton shear thickening power-law fluid compared to the Newton fluid or shear thinning fluid can achieve higher material removal rate (MRR). MRR will further increase with the increasing of viscosity index n. When n is equal to 2 and consistency index K is equal to 0.32, MRR is exponential growth trend with the increase of U, which shows that increasing velocity improves the machining efficiency. Then a machining experiment of GCr15 bearing steel curved surface material is carried out on a shear thickening polishing machining system, the surface roughness of workpiece is decreased from R_a 105.95 nm to R_a 5.99 nm after 90 min processing, and mirror effect can be achieved. MRR of GCr15 (bearing steel) is up to 2.1 μm/h. The average error between the material removal theoretical value and processing experiment result is only 6.12%. The validation of established material removal mathematics model is verified.

Key words: material removal mathematics model, non-Newtonian power-law fluid, polishing, Preston equation, shear thickening polishing(STP)

CLC Number:

TH16

LI Min, LÜ Binghai, YUAN Julong, DONG Chenchen, DAI Weitao. Material Removal Mathematics Model of Shear Thickening Polishing[J]. Journal of Mechanical Engineering, 2016, 52(7): 142-151.

References

[1] BRINKSMEIER E,MUTLUGUNES Y,KLOCKE F,et al. Ultra-precision grinding[J]. CIRP Annals - Manufacturing Technology,2010 (59)：652-671.
[2] 李敏,袁巨龙,吴喆,等. 复杂曲面零件超精密加工方法的研究进展[J]. 机械工程学报,2015,51(5)：178-191.
LI Min,YUAN Julong,WU Zhe,et al. Progress in ultra-precision machining methods of complex curved parts[J]. Journal of Mechanical Engineering,2015,51(5)：178-191.
[3] 李圣怡,戴一帆. 大中型光学非球面镜制造与测量新技术[M]. 北京：国防工业出版社,2011.
LI Shengyi,DAI Yifan. New technology for manufacturing and measurement of large and middle-scale aspheric surfaces[M]. Beijing：National Defense Industrial Press,2011.
[4] 周志雄,周秦源,任莹晖. 复杂曲面加工技术的研究现状与发展趋势[J]. 机械工程学报,2010,46(17)：105-113.
ZHOU Zhixiong,ZHOU Qinyuan,REN Yinghui. Current research and development trends of complex surface machining technology[J]. Journal of Mechanical Engineering,2010,46(17)：105-113.
[5] 袁哲俊,王先逵. 精密和超精密加工技术 [M]. 第二版北京：机械工业出版社,2007.
YUAN Zhejun,WANG Xiankui. The technology of precision machining and ultra-precision machining [M]. 2th ed. Beijing：China Machine Press,2007.
[6] 计时鸣,李琛,谭大鹏,等. 基于Preston方程的软性磨粒流加工特性[J]. 机械工程学报,2011,47(17)：156-163.
JI Shiming,LI Chen,TAN Dapeng,et al. Study on machinability of softness abrasive flow based on Preston equation[J]. Journal of Mechanical Engineering,2011,47(17)：156-163.
[7] MUHAMMAD A,MUSTAFIZUR R,WONG Y S. A study on the effect of tool-edge radius on critical machining characteristics in ultra-precision milling of tungsten carbide[J]. The International Journal of Advanced Manufacturing Technology,2013,67(5-8)：1257-1265.
[8] 董波,李维仲,冯玉静,等. 幂律流体圆柱绕流的格子波尔兹曼模拟[J]. 力学学报,2014,46(1)：44-53.
DONG Bo,LI Weizhong,FENG Yujing,et al. Lattice Boltzmann simulation of a power-law fluid past a circular cylinder[J]. Chinese Journal of Theoretical and Applied Mechanics,2014,46(1)：44-53.
[9] 张道成. 水-沙幂律流体的流动(层流)特性研究-水石流的幂律体模型(上)[J]. 四川联合大学学报,1997,1(2)：88-94.
ZHANG Daocheng. Study on laminar flow properties of water-sediment power-law fluid- the power-law model of water-rock flow(I)[J]. Journal of Sichuan Union University,1997,1(2)：88-94.
[10] 章梓雄,董曾南. 黏性流体力学[M]. 2版. 北京：清华大学出版社,2011.
ZHANG Zixiong,DONG Cengnan. Viscous fluid mechanics[M]. 2nd ed. Beijing：Tsinghua University Press,2011.
[11] 袁祖强,刘建华. 含油轴承非牛顿流体动力润滑理论的推导[J]. 南京化工大学学报,2001,23(2)：67-70.
YUAN Zuqiang,LIU Jianhua. Theoretical derivation of hydrodynamic lubrication of porous metal bearing lubricatied with non-newtonian fluid[J]. Journal of Nanjing University of Chemical Technology,2001,23(2)：67-70.
[12] TSAI K M,WANG P J. Comparisons of neural network models on material removal rate in electrical discharge machining[J]. Journal of Materials Processing Technology,2001,117 (1-2)：111-124.

[1]	DONG Xiaoxing, ZHU Tieyu, LU Congda, JIN Mingsheng. Study on the Evolution Mechanism of Workpiece Surface Morphology Based on the Ball-column Electrorheological Polishing Tool [J]. Journal of Mechanical Engineering, 2024, 60(9): 364-373.
[2]	DENG Jianxin, YUAN Bangyi, HUANG Qiulin, DING Dukun, XIN Manyu, LIU Guangming. Review on the Key Technologies of Complex Surfaces Polishing Based on Robots [J]. Journal of Mechanical Engineering, 2024, 60(7): 1-21.
[3]	HUA Dongpeng, ZHOU Qing, WANG Wan, LI Shuo, WANG Zhijun, WANG Haifeng. A Molecular Dynamics Simulation on the Subsurface Damage Mechanism in the Nano-polishing Process of Silicon Carbide [J]. Journal of Mechanical Engineering, 2024, 60(5): 231-240.
[4]	GUO Jiang, ZHANG Pengfei, YANG Zhe, ZHAO Yong, LI Linguang, JING Zhao, ZHANG Meng, PANG Guibing. Investigation on High-performance Non-contact Shape Profiling Polishing for Array Diffuser Mold [J]. Journal of Mechanical Engineering, 2024, 60(1): 127-136.
[5]	CHEN Lei, LIU Yangqin, TANG Chuan, JIANG Yilong, SHI Pengfei, QIAN Linmao. Research Advance on Material Removal at Microscale towards Ultra-precision Manufacturing [J]. Journal of Mechanical Engineering, 2023, 59(23): 229-264.
[6]	LI Tao, HUANG Weiqi, LONG Gui, YANG Sishuo, ZHANG Jianguo, XIAO Junfeng, XU Jianfeng. Surface Topography Evolution of Single Crystal Silicon in Laser Polishing [J]. Journal of Mechanical Engineering, 2023, 59(21): 52-64.
[7]	ZHANG Jiarong, WANG Han, ZHUO Shaomu, YAO Honghui, ZHU Xiangyou, MA Shuaijie, ZHAN Daohua. Polishing of Micro Aspheric Mold Based on Viscoelastic Spherical Small Polishing Tool [J]. Journal of Mechanical Engineering, 2023, 59(17): 300-309.
[8]	GUO Yuanfan, YIN Shaohui, HUANG Shuai. Study on Machining Characteristic and its Mechanism of Magnetorheological Polishing with Halbach Array and Other Excitation Modes [J]. Journal of Mechanical Engineering, 2023, 59(15): 341-353.
[9]	YAN Qiusheng, CAI Zhihang, PAN Jisheng. Study on the Polishing Forces Characteristics of Magnetorheological Variable Gap Dynamic Pressure Polishing [J]. Journal of Mechanical Engineering, 2023, 59(1): 231-241.
[10]	LI Zhen, ZHAO Huan, WANG Hui, DING Han. Research on Contact Steady-state Adaptive Force Tracking of Robot Grinding and Polishing [J]. Journal of Mechanical Engineering, 2022, 58(9): 200-209.
[11]	HE Chunlei, REN Chengzu, WANG Shuqi, ZONG Wenjun. Research Progress of Diffraction Effect on the Ultra-precision Cutting Surface [J]. Journal of Mechanical Engineering, 2022, 58(3): 266-275.
[12]	HANG Tao, CHANG Pengfei, LI Ming. Research Progress of Material Removal Mechanism in Chemical Mechanical Planarization for Metal Interconnection Layer of Chips [J]. Journal of Mechanical Engineering, 2022, 58(2): 147-158.
[13]	YUAN Julong, WANG Jinhu, Lü Binghai, WANG Xu, HANG Wei. Force Rheological Polishing Technology [J]. Journal of Mechanical Engineering, 2022, 58(15): 21-30.
[14]	ZHANG Feihu, WANG Yiren, LIAO Defeng, REN Lele, LI Chen. Study on the Influence of Temperature Distribution in the Optical Elements on the Surface Shape and Its Control Method during Full Aperture Polishing [J]. Journal of Mechanical Engineering, 2022, 58(15): 46-54.
[15]	QIAO Guochao, DAI Lida, ZHANG Zhengyan. Predictive Model of Surface Roughness of Laser-assisted Magnetorheological Finishing with Spherical Tool [J]. Journal of Mechanical Engineering, 2022, 58(15): 166-176.