Abstract
Computer-controlled ultra-precision polishing technology is widely used for high-quality surface processing. However, its polishing tool has some shortcomings, such as limited adaptability and more surface damage to the complex surface. Therefore, a new smart material-based abrasive tool named magnetorheological elastic polishing composites (MREPCs) and its flexible polishing method is proposed. This study first prepared MREPCs and developed a polishing tool for MREPCs. Then, the material properties of MREPCs were obtained by theoretical and experimental analysis, and the tool influence function (TIF) of the hemispherical MRPECs was established according to the Hertz contact theory, the variable rheological theory, and the Preston equation. Finally, the TIF and the polishing performance of MREPCs were verified by polishing experiments. The results show that the theoretical and the experimentally measured TIF models have a high coincidence, and the developed MREPCs can remove surface material with high precision. The above preliminary study indicates that MREPCs are promising for ultra-precision machining of small-sized parts with complex profiles.
Highlights
Ultra-precision polishing technology and processes have always been hotspots of research
A flexible polishing method based on magnetorheological elastic polishing composites (MREPCs) was proposed, and the performance of the MREPCs was analyzed through experiment and simulation
The conclusions are as follows: (1) The experimental results show that the external magnetic field can change the stiffness of MREPCs, which is mainly manifested as the increase of young's modulus of MREPCs with the increase of magnetic field and the increase of magneto-compression force required under the same strain compression
Summary
Ultra-precision polishing technology and processes have always been hotspots of research. There are many studies on the establishment of the material removal function model of abrasive particle fixation or semi-fixation polishing tools, almost all based on the Preston's equation. CAO et al established a multi-scale theoretical model of airbag polishing removal characteristics from the perspective of single abrasive particle wear, and studied the formation process of optical surface [15, 16]. According to the previous research status, this study will establish a material removal function model of MREPCs polishing tools based on the Preston's equation. A material removal function model of MREPCs during fixed-point polishing was established based on the Preston's equation, Hertz contact theory, and magneto-rheological elastic material magnetogenic stiffness mechanism. The model was verified by simulation and experiment, and the influencing factors of material removal were analyzed
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