Theoretical and experimental investigation of material removal rate in magnetorheological shear thickening polishing of Ti-6Al-4V alloy

IF 2.4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING Journal of Manufacturing Science and Engineering-transactions of The Asme Pub Date : 2023-11-03 DOI:10.1115/1.4063984
Yebing Tian, Zhen Ma, Shadab Ahmad, Cheng Qian, Xifeng Ma, Xiangyu Yuan, Zenghua Fan
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Abstract

Abstract Magnetorheological shear thickening polishing (MRSTP) is a novel multi-field compound polishing method that combines the shear-thickening effect and the magnetorheological effect. It has great potential as an ultra-precise machining for complex surfaces. However, there is absence of the correlation between the material removal and the rheological properties of the polishing media leads to difficulties for further improvement in polishing efficiency and quality in MRSTP. In this paper, the material removal model for MRSTP was established based on magneto-hydrodynamics, non-Newtonian fluid kinematics and microscopic contact mechanics. It combines the material removal model for single abrasive and statistical model of active abrasives. On comparing the experimental and theoretical results, it showed that the developed material removal model can accurately predict the material removal depth of the workpiece under different processing parameters (rotational speed of rotary table and magnetic field strength). The average prediction error was less than 5.0%. In addition, the analysis of the rheological behavior and fluid dynamic pressure of the polishing media reveals the coupling effect between the magnetic, stress and flow fields. This provides theoretical guidance for the actual processing of MRSTP. Finally, the maximum material removal rate of 3.3 μm/h was obtained on the cylindrical surface of the Ti-6Al-4V workpiece using the MRSTP method. The result shows that the MRSTP method has great potential in the field of ultra-precision machining of difficult-to-machine materials.
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Ti-6Al-4V合金磁流变剪切增厚抛光材料去除率的理论与实验研究
摘要磁流变剪切增厚抛光(MRSTP)是一种将剪切增厚效应与磁流变效应相结合的新型多场复合抛光方法。作为一种复杂曲面的超精密加工,它具有巨大的潜力。然而,由于材料去除与抛光介质流变特性之间缺乏相关性,使得MRSTP在进一步提高抛光效率和质量方面存在困难。基于磁流体力学、非牛顿流体运动学和微观接触力学,建立了MRSTP的材料去除模型。它结合了单个磨料的材料去除模型和活性磨料的统计模型。实验与理论结果对比表明,所建立的材料去除模型能够准确预测工件在不同加工参数(转台转速和磁场强度)下的材料去除深度。平均预测误差小于5.0%。此外,对抛光介质的流变特性和动压进行了分析,揭示了磁场、应力场和流场之间的耦合效应。这为MRSTP的实际处理提供了理论指导。最后,采用MRSTP方法在Ti-6Al-4V工件的圆柱表面获得了3.3 μm/h的最大材料去除率。结果表明,MRSTP方法在难加工材料的超精密加工领域具有很大的潜力。
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来源期刊
CiteScore
6.80
自引率
20.00%
发文量
126
审稿时长
12 months
期刊介绍: Areas of interest including, but not limited to: Additive manufacturing; Advanced materials and processing; Assembly; Biomedical manufacturing; Bulk deformation processes (e.g., extrusion, forging, wire drawing, etc.); CAD/CAM/CAE; Computer-integrated manufacturing; Control and automation; Cyber-physical systems in manufacturing; Data science-enhanced manufacturing; Design for manufacturing; Electrical and electrochemical machining; Grinding and abrasive processes; Injection molding and other polymer fabrication processes; Inspection and quality control; Laser processes; Machine tool dynamics; Machining processes; Materials handling; Metrology; Micro- and nano-machining and processing; Modeling and simulation; Nontraditional manufacturing processes; Plant engineering and maintenance; Powder processing; Precision and ultra-precision machining; Process engineering; Process planning; Production systems optimization; Rapid prototyping and solid freeform fabrication; Robotics and flexible tooling; Sensing, monitoring, and diagnostics; Sheet and tube metal forming; Sustainable manufacturing; Tribology in manufacturing; Welding and joining
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