In-situ Fabrication of Microstructure Tool with Abrasive Uniform by Electrostatic Spray Deposition

doi:10.3901/JME.2021.07.262

Abstract

Abstract: A method of in-situ fabrication of microstructure tool with abrasive uniform by ESD is proposed. Two dimensional simulation model of electrostatic spray microgroove is established by using AC/DC module and particle tracking module in COMSOL Multiphysics. The electric field characteristics, spray characteristics and deposition characteristics under nozzle-ring electrodes are studied. The optimized parameters of microgroove height to width ratio ≤1, micro channel depth ≤1 mm, electrostatic voltage ≤-6 kV and receiving distance ≥40 mm are obtained. The static liquid is prepared by light curing resin, polysorbate-80 and kerosene in the proportion of 4:3:1, and the single crystal diamond powder is added for electrostatic spraying. Dirichlet tessellation is used to evaluate the distribution uniformity of abrasive particles in different injection time and radial positions. It was concluded that the distribution uniformity of abrasive particles is more than 70% in the radius range of 2.5 mm with the injection center to obtain the appropriate size of the microstructure tool. The reasonable parameters of the microgroove are obtained by analyzing the influence of the depth and width of the microstructure on the deposition rate. The microstructural characteristics of the abrasive tool are complete. The deviation between the microgroove width of the abrasive tool and the workpiece is ≤2.87%, and the height deviation is ≤1.09%. The in-situ fabrication of microstructure abrasives tool by ESD has the characteristics with uniform distribution of abrasive particles and controllable morphology. This method provides a new idea and technology for microstructure surface machining.

Key words: electrostatic spray deposition, microstructure abrasive tool, diamond powder, uniform distribution, COMSOL Multiphysics

CLC Number:

TG58

CHEN Fengjun, CHEN Haizhen. In-situ Fabrication of Microstructure Tool with Abrasive Uniform by Electrostatic Spray Deposition[J]. Journal of Mechanical Engineering, 2021, 57(7): 262-272.

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