Model modification and influence of edge effect on effective area of giant electro-rheological polishing using plate electrodes

IF 3.7 3区材料科学 Q1 INSTRUMENTS & INSTRUMENTATION

Smart Materials and Structures Pub Date : 2024-09-06 DOI:10.1088/1361-665x/ad74c0

Haihong Ai, Pingfa Ren, Kun Wang, Tianqi Song, Zhanshan Wang

{"title":"Model modification and influence of edge effect on effective area of giant electro-rheological polishing using plate electrodes","authors":"Haihong Ai, Pingfa Ren, Kun Wang, Tianqi Song, Zhanshan Wang","doi":"10.1088/1361-665x/ad74c0","DOIUrl":null,"url":null,"abstract":"Giant electro-rheological polishing (GERP) is recognized as an innovative ultra-precision machining technology with significant potential. However, the pronounced edge effect within the GERP’s polishing gap can introduce errors in calculating the effective area and designing the electrode structure. This, in turn, may lead to under-polishing and an increased risk of insulation breakdown. In this study, COMSOL was employed to investigate the electric field distribution characteristics within the polishing gap. This exploration aimed to refine the calculation model of the effective area, optimize the plate electrodes’ structure and size, and diminish the likelihood of insulation breakdown. Through systematic finite element simulations, the impact of polishing voltage, inter-electrode gap, and plate length on the edge effect was thoroughly analyzed to ascertain its influence range. The simulation findings revealed that, while maintaining a constant inter-electrode gap for the tool electrode, variations in the polishing gap, polishing voltage, and plate length within specific ranges resulted in an edge effect influence range of approximately 1 mm. Moreover, when the machining gap, polishing voltage, and plate length remained unchanged, the edge effect influence range increased proportionally with the electrode gap within a specific range, approximately equivalent to the size of the electrode gap. Experimental validation of the giant electro-rheological effect confirmed the existence and influence range of the edge effect, aligning with the finite element simulation results. Ultimately, modifications to the calculation model of the effective area were proposed, along with a solution to optimize the electrode size and structure, with the objective of reducing the probability of insulation breakdown. In practical applications, this work can provide a valuable reference for electrode structure design, insulation breakdown improvement and parameter selection.","PeriodicalId":21656,"journal":{"name":"Smart Materials and Structures","volume":"100 1","pages":""},"PeriodicalIF":3.7000,"publicationDate":"2024-09-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Smart Materials and Structures","FirstCategoryId":"88","ListUrlMain":"https://doi.org/10.1088/1361-665x/ad74c0","RegionNum":3,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"INSTRUMENTS & INSTRUMENTATION","Score":null,"Total":0}

引用次数: 0

Abstract

Giant electro-rheological polishing (GERP) is recognized as an innovative ultra-precision machining technology with significant potential. However, the pronounced edge effect within the GERP’s polishing gap can introduce errors in calculating the effective area and designing the electrode structure. This, in turn, may lead to under-polishing and an increased risk of insulation breakdown. In this study, COMSOL was employed to investigate the electric field distribution characteristics within the polishing gap. This exploration aimed to refine the calculation model of the effective area, optimize the plate electrodes’ structure and size, and diminish the likelihood of insulation breakdown. Through systematic finite element simulations, the impact of polishing voltage, inter-electrode gap, and plate length on the edge effect was thoroughly analyzed to ascertain its influence range. The simulation findings revealed that, while maintaining a constant inter-electrode gap for the tool electrode, variations in the polishing gap, polishing voltage, and plate length within specific ranges resulted in an edge effect influence range of approximately 1 mm. Moreover, when the machining gap, polishing voltage, and plate length remained unchanged, the edge effect influence range increased proportionally with the electrode gap within a specific range, approximately equivalent to the size of the electrode gap. Experimental validation of the giant electro-rheological effect confirmed the existence and influence range of the edge effect, aligning with the finite element simulation results. Ultimately, modifications to the calculation model of the effective area were proposed, along with a solution to optimize the electrode size and structure, with the objective of reducing the probability of insulation breakdown. In practical applications, this work can provide a valuable reference for electrode structure design, insulation breakdown improvement and parameter selection.

查看原文本刊更多论文

使用板式电极进行巨型电流变抛光的模型修改和边缘效应对有效面积的影响

巨型电流变抛光（GERP）被认为是一种具有巨大潜力的创新型超精密加工技术。然而，GERP 抛光间隙内明显的边缘效应会在计算有效面积和设计电极结构时产生误差。这反过来又可能导致抛光不足，增加绝缘击穿的风险。本研究采用 COMSOL 来研究抛光间隙内的电场分布特征。这一研究旨在完善有效区域的计算模型，优化平板电极的结构和尺寸，降低绝缘击穿的可能性。通过系统的有限元模拟，深入分析了抛光电压、电极间间隙和平板长度对边缘效应的影响，以确定其影响范围。模拟结果表明，在保持工具电极间隙不变的情况下，抛光间隙、抛光电压和平板长度在特定范围内的变化会导致边缘效应的影响范围达到约 1 毫米。此外，当加工间隙、抛光电压和平板长度保持不变时，边缘效应影响范围在特定范围内随电极间隙成比例增加，大约相当于电极间隙的大小。巨型电流变效应的实验验证证实了边缘效应的存在和影响范围，与有限元模拟结果一致。最终，我们提出了对有效面积计算模型的修改，以及优化电极尺寸和结构的解决方案，目的是降低绝缘击穿的概率。在实际应用中，这项工作可为电极结构设计、绝缘击穿改善和参数选择提供有价值的参考。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

求助全文

约1分钟内获得全文求助全文

来源期刊

Smart Materials and Structures 工程技术-材料科学：综合

CiteScore

7.50

自引率

12.20%

发文量

317

审稿时长

3 months

期刊介绍： Smart Materials and Structures (SMS) is a multi-disciplinary engineering journal that explores the creation and utilization of novel forms of transduction. It is a leading journal in the area of smart materials and structures, publishing the most important results from different regions of the world, largely from Asia, Europe and North America. The results may be as disparate as the development of new materials and active composite systems, derived using theoretical predictions to complex structural systems, which generate new capabilities by incorporating enabling new smart material transducers. The theoretical predictions are usually accompanied with experimental verification, characterizing the performance of new structures and devices. These systems are examined from the nanoscale to the macroscopic. SMS has a Board of Associate Editors who are specialists in a multitude of areas, ensuring that reviews are fast, fair and performed by experts in all sub-disciplines of smart materials, systems and structures. A smart material is defined as any material that is capable of being controlled such that its response and properties change under a stimulus. A smart structure or system is capable of reacting to stimuli or the environment in a prescribed manner. SMS is committed to understanding, expanding and dissemination of knowledge in this subject matter.