Study on the inhibition mechanism and removal mechanism of non-uniform removal of composite materials by multiphysics coupling polishing method

Abstract

The non-uniform characteristics of SiCp/Al are one of the reasons why it is difficult to process, which leads to surface and sub-surface damage and non-uniform removal of SiCp/Al after polishing. Introducing impact effects through the vibration field to improve the non-uniform removal problem in SiCp/Al machining has been proven effective. However, the mechanisms of the effects of the vibration field on rheological properties and the generation of impact effects are still unclear. Therefore, the non-resonant vibration-assisted wheeled magnetorheological polishing (NVWMRP) method is used to process SiCp/Al, the mechanism of the coupling field (magnetic field, vibration field, and flow field) on the rheological characteristics of magnetorheological polishing fluid (MRPF) is analysed by simulation and experiment. The vibration field promotes the viscous flow of MRPF, and the viscous wave is the main reason for the impact effect. Based on the rheological test results, the polishing force model in the multi-physics coupling environment is established. The SiCp/Al polishing experiment verifies the theory's correctness and explores the polishing process. NVWMRP has a positive significance in reducing the height of the SiCp/Al step. The surface roughness Sa is reduced to 112 nm. This study explains the mechanism of impact effect and provides guidance for applying vibration field-assisted machining technology in magnetorheological polishing and improving the processability of composites.