Effect mechanism of multi-phase coupling on particle behaviors in magnetorheological foam plane finishing process

Abstract

In this study, the effect mechanism of multi-phase coupling on particle behaviors in magnetorheological foam plane finishing (MRFPF) was researched to realize the collaborative control of particle distribution uniformity and polishing quality. To reach the goal, particle behaviors in MRFPF under the effect of fluid-solid coupling in magnetorheological foam were numerically studied by molecular dynamics (MD) simulation based on the force analysis that considering pressure drop due to fluid flow in foam pores. According to the simulation results, the influence law of different processing parameters on the radial distribution uniformity of particles was analyzed based on experimental analysis method. The results show that the polishing disk rotation speed and foam porosity have a positive effect on the radial distribution uniformity of particles, while the foam aperture affects little, and the greatest influence is produced by foam porosity which followed by polishing disk rotation speed and foam aperture. What's more, an optimal parameter combination with foam porosity 0.7, polishing disk rotation speed 30 rpm, and foam aperture 1 mm was determined by comprehensively considering the fluidity of MRPF and self-excited characteristics of abrasive particles in MRPF. Moreover, the advantages of MRFPF in improving the particle distribution uniformity and surface finishing quality to that of magnetorheological finishing were verified from numerical simulations and experiments.