Optimization Study of Shear-Thickening Polishing Technology in the Passivation Process of Spiral-Fluted Tap Edge Based on Simulation Analysis

Abstract

This study examines the effectiveness of shear-thickening polishing technology in passivating high-speed steel tap edges through simulation. It analyzes the impact of workpiece speed (V), rotary speed (V′), and inclination angle (θ) on pressure distribution and surface roughness during edge preparation. The simulation shows a peak pressure of 8723.236 Pa at an 80° angle, leading to uniform distribution and reduced surface roughness to 12 nm after 25 min of polishing. A multiresponse optimization method identifies optimal edge preparation conditions at maximum pressure, enhancing edge consistency and minimizing roughness. A mathematical model and universal empirical formula relate edge preparation rate to inclination angle, applicable to various curved edge tools. A regression model explores relationships among inclination angle, rotational speed, and edge blunting radius. The study finds that an inclination angle of 80°, a spin speed of 10 rad min⁻¹, and a disk speed of 80 rad min⁻¹ can control the edge radius to 30 μm. The research confirms the simulation's reliability and highlights the inclination angle's significant effect on edge radius, providing a theoretical and practical guide for applying shear-thickening polishing technology in tool edge preparation.