Study on the Evolution Mechanism of Workpiece Surface Morphology Based on the Ball-column Electrorheological Polishing Tool

doi:10.3901/JME.2024.09.364

Abstract

Abstract: Based on the characteristics of electrorheological liquid, a ball-column electrorheological polishing tool is developed to investigate the evolution mechanism of workpiece surface morphology. The material removal depth model and workpiece surface profile evolution model are established according to the Preston equation and Hertzian elastic contact friction theory. The fixed-point processing experiments show that the workpiece surface profile lines are similar to the predicted under theory, which is calculated as the deviation of the depth material removal rate with a maximum deviation value of 55 nm/min. The moving processing experiments show that the width and depth of the calculated contour are close to the measured dimensions of the actual processing area, and the surface roughness decreased from Ra 78 nm before processing to Ra 14 nm after processing. The polishing efficiency increases with the increase of voltage or rotational speed, and the stable value of surface roughness of the workpiece depends on the abrasive size. The smaller the cutting edge of the abrasive size, the lower the final surface roughness after polishing. When the polishing gap increases, the workpiece surface profile gradually transforms from “U” to “W”, and the transformation process is affected by the voltage and rotational speed, where voltage is dominant, followed by rotational speed. The analysis of evolution mechanism of workpiece surface morphology in ball-column electrorheological polishing provides a theoretical basis for electrorheological profile trimming.

Key words: electrorheological polishing, micromachining, contour profiles, electric field-assisted

CLC Number:

TG161

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.

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