Abstract
In the process of surface treatment, steel wire brush can not only efficiently remove surface contaminants, such as deteriorated paint film and rust, but also increase the adhesive strength. However, the associated brush mechanics of material removal is still not clear. In order to reveal the brush mechanics of material removal, this paper assumed the tip of steel wire were ball–cone shaped, constructed contact force model, and calculated the brush grinding force under different process conditions based on finite element approach. The simulated results show that the brush grinding can be changed from plastic plowing to chip formation when the penetration depth is increased to 10 μm, then changed from chip formation to plastic plowing when the inclination angle is increased to 30°, respectively. The simulated value of brush force rises with the increasing penetration depth and inclination angle, which was consistent with the experimentally obtained values, and the relative errors are within 9%. The quantity of material removal increases with the ascending of penetration depth, and decreases with the ascending of inclination angle. This paper provides guidance to understand the mechanics of material removal, predict the brush grinding force, and contribute well to an automatic grinding control application.
Highlights
IntroductionMetal parts often suffer from the rust, flaking paint and fatigue damage
During manufacture applications, metal parts often suffer from the rust, flaking paint and fatigue damage
In order to analyze the associated mechanics of material removal, this paper assumed the tip of steel wire as ball–cone shape, and investigated the brush grinding aluminum alloy based on finite element method
Summary
Metal parts often suffer from the rust, flaking paint and fatigue damage. A steel wire brush can effectively perform surface treatment such as grinding,[1,2] hammering,[3,4] deburring,[5,6] rust and paint removal. Steel wire brushes are widely used on handhold grinders without comprehensive control techniques, and intelligent grinding robots with brush tools are still rare in the market due to difficulties involved in the end effectors control.[7] The research on brush tools mainly included toothbrush,[8,9] and road sweeping brush with straight rectangular tines.[10] For example, the studies on the road sweeping brush[11] have developed the methodology of modeling brush deformation to analyze brush contact geometry and contact force, and the results were further summarized into mathematical models, which were utilized in experiments and dynamics analysis. Uhlmann and Hoyer[13] carried out the surface finishing of zirconium dioxide with
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