Abstract
As a fluid-based precise processing method, soft abrasive flow processing has been widely used in advanced electromechanical systems, complex mold manufacturing, and other engineering fields. Because of the low volume fraction of abrasive particles and micro-force/cutting removal characteristics, there exists a potential improvement in terms of processing efficiency and uniformity. In view of the above problems, this article presents an ultrasonic-assisted soft abrasive flow processing method. Based on the realizable k–ε turbulence model and the mixture flow model, an ultrasonic coupling enhancement dynamic model for soft abrasive flow is set up, and the kinetic energy transport equation of realizable k–ε turbulence model can be revised. Using particle image velocimetry technology, an on-line observation experimental platform for ultrasonic-assisted soft abrasive flow is developed to conduct the real-time acquisition of abrasive flow state and particle distribution in a constrained flow passage. An ultrasonic-assisted soft abrasive flow processing experimental platform is established to complete the processing experiment. The experimental results show that the ultrasonic excitation vibration can effectively enhance the turbulence intensity and distribution uniformity of the abrasive flow, the average processing time can be shortened by more than 6 h, and a better surface quality can be obtained.
Highlights
Mold is an important production tool to create a variety of non-metal and metal parts, and a basic process equipment for an industrial production.[1,2,3] During the mold manufacturing process, to eliminate the traces left by cutting tools, electric sparks, and other processing tools, polishing is an important procedure of the mold surface engineering
The required research works have been performed, and the main conclusions are as follows: 1. Based on the realizable kÀe turbulence model and the mixture multiphase flow model, we set up a fundamental dynamic model of ultrasonic coupling enhancement for SAF
In the dissipative transport equation, the external friction force caused by the shear stress t is taking into consideration; the reliability of the modified realizable kÀe model for the simulation of the loaded ultrasonic vibration is improved
Summary
Mold is an important production tool to create a variety of non-metal and metal parts, and a basic process equipment for an industrial production.[1,2,3] During the mold manufacturing process, to eliminate the traces left by cutting tools, electric sparks, and other processing tools, polishing is an important procedure of the mold surface engineering. As can be seen from the curves, the ultrasonic coupling method can effectively change the velocity distribution in the near wall of the constrained flow path, and the average speed can be doubly increased, which improves the removal efficiency of the abrasive flow in the near wall. It can be seen from the curve in the figure that the proposed method in this article can effectively enhance the turbulent kinetic energy distribution in the near-wall region of constrained flow passage, and a five times of average turbulent kinetic energy amplitude can be got. For verifying the effectiveness of the proposed USAF processing method, a processing experimental platform is established, which consists of a SAF mixer, a solidliquid two-phase diaphragm pump, a workpiece, a constrained flow passage, a valve pipeline, and an ultrasonic vibration exciter. There are a total of 10 sets of measuring records during 20 h
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