{"title":"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","authors":"Yebing Tian, Zhen Ma, Shadab Ahmad, Cheng Qian, Xifeng Ma, Xiangyu Yuan, Zenghua Fan","doi":"10.1115/1.4063984","DOIUrl":null,"url":null,"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.","PeriodicalId":16299,"journal":{"name":"Journal of Manufacturing Science and Engineering-transactions of The Asme","volume":"28 1","pages":"0"},"PeriodicalIF":2.4000,"publicationDate":"2023-11-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":"{\"title\":\"Theoretical and experimental investigation of material removal rate in magnetorheological shear thickening polishing of Ti-6Al-4V alloy\",\"authors\":\"Yebing Tian, Zhen Ma, Shadab Ahmad, Cheng Qian, Xifeng Ma, Xiangyu Yuan, Zenghua Fan\",\"doi\":\"10.1115/1.4063984\",\"DOIUrl\":null,\"url\":null,\"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.\",\"PeriodicalId\":16299,\"journal\":{\"name\":\"Journal of Manufacturing Science and Engineering-transactions of The Asme\",\"volume\":\"28 1\",\"pages\":\"0\"},\"PeriodicalIF\":2.4000,\"publicationDate\":\"2023-11-03\",\"publicationTypes\":\"Journal Article\",\"fieldsOfStudy\":null,\"isOpenAccess\":false,\"openAccessPdf\":\"\",\"citationCount\":\"0\",\"resultStr\":null,\"platform\":\"Semanticscholar\",\"paperid\":null,\"PeriodicalName\":\"Journal of Manufacturing Science and Engineering-transactions of The Asme\",\"FirstCategoryId\":\"1085\",\"ListUrlMain\":\"https://doi.org/10.1115/1.4063984\",\"RegionNum\":3,\"RegionCategory\":\"工程技术\",\"ArticlePicture\":[],\"TitleCN\":null,\"AbstractTextCN\":null,\"PMCID\":null,\"EPubDate\":\"\",\"PubModel\":\"\",\"JCR\":\"Q3\",\"JCRName\":\"ENGINEERING, MANUFACTURING\",\"Score\":null,\"Total\":0}","platform":"Semanticscholar","paperid":null,"PeriodicalName":"Journal of Manufacturing Science and Engineering-transactions of The Asme","FirstCategoryId":"1085","ListUrlMain":"https://doi.org/10.1115/1.4063984","RegionNum":3,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q3","JCRName":"ENGINEERING, MANUFACTURING","Score":null,"Total":0}
Theoretical and experimental investigation of material removal rate in magnetorheological shear thickening polishing of Ti-6Al-4V alloy
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.
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