Abstract
Abstract The application of a specific rheological polishing slurry is proposed first for high-efficiency machining of steel materials to achieve high-quality ultraprecision finished surfaces. The rheology of the polishing slurry was explored to show that the non-Newtonian medium with certain parameters of content components exhibits shear-thickening behavior. Then the new high-efficiency nano polishing approach is applied to process spherical surfaces of bearing steel. Several controllable parameters such as shear rheology, abrasive data, rotational speed, and processing time are experimentally investigated in this polishing process. A special finding is that the surface roughness and material removal rate can increase simultaneously when a small abrasive size is applied due to the thickening mechanism during the shearing flow of slurries. Excessive abrasives can decrease surface quality due to the uneven agglomeration of particles scratching the surface. Under optimized conditions, a high-accuracy spherical bearing steel surface with a roughness of 12.6 nm and roundness of 5.3 μm was achieved after a processing time of 2.5 h. Thus, a potential ultraprecision machining method for target materials is obtained in this study.
Highlights
The application of a specific rheological polishing slurry is proposed first for high-efficiency machining of steel materials to achieve high-quality ultraprecision finished surfaces
Jones [3] developed the computer-controlled optical surfacing (CCOS) technology to achieve the shaping of high-precision surfaces
The material removal mechanism and polishing quality were characterized with a profilometer
Summary
Abstract: The application of a specific rheological polishing slurry is proposed first for high-efficiency machining of steel materials to achieve high-quality ultraprecision finished surfaces. High-efficiency deterministic finishing method is an important factor in the entire manufacturing process In this sense, Jones [3] developed the computer-controlled optical surfacing (CCOS) technology to achieve the shaping of high-precision surfaces. Law et al [4] developed a CCOS system for correcting form errors on aspheric surfaces and obtained a 55 mm diameter aspheric workpiece with peak‐to‐valley (PV) error of 662 nm and rootmean-square (RMS) of 115 nm Some polishing methods, such as magnetorheological finishing (MRF) [5], bonnet polishing [6], and chemical mechanical polishing (CMP) [7] can successfully remove tiny amounts of material and at the same time they hardly induce fracture in the machined material. A potential ultraprecision machining method for the targeted materials is obtained in this study
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