Material Removal Characteristics and Predictive Models for Magnetorheological Shear Thickening Polishing Method

doi:10.3901/JME.2024.23.365

Abstract

Abstract: Magnetorheological shear thickening polishing (MRSTP) is a novel multi-field hybrid polishing method combined dual stimulus responses of shear thickening and magnetisation enhancement, which can achieve efficient and precise polishing for difficult-to-machine materials. However, the relationship between the microscopic material removal behaviours of the MRSTP and the rheological characteristics of the polishing media remain unclear. A predictive material removal model is established with the approaches of magnetorheological fluid dynamics, non-Newtonian fluid kinematics, and microscale contact mechanics, based on integration the single-grit material removal model with the statistical model of active abrasives. The rheological properties of the polishing media are analysed. The law of the influence of processing parameters on the fluid pressure applied to the workpiece surface is investigated. The coupling effects between the magnetic field and the stress field are deeply explored to reveal the material removal mechanism of MRSTP. A maximum material removal rate (MRR) of 2.7 μm/h is obtained on the Ti-6Al-4V workpiece surface. The relative error between the theoretical and experimental MRR is 18.95%, verifying the validity of the MRR model. The results show that the MRSTP method is great potential for achieving efficient processing for difficult-to-machine materials.

Key words: magnetorheological shear thickening polishing, material removal mechanism, prediction model, fluid dynamics, Ti-6Al-4V

CLC Number:

TG73

TIAN Yebing, MA Zhen, QIAN Cheng, AHMAD S, MA Xifeng, YUAN Xiangyu, FAN Zenghua. Material Removal Characteristics and Predictive Models for Magnetorheological Shear Thickening Polishing Method[J]. Journal of Mechanical Engineering, 2024, 60(23): 365-376.

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