Modeling and simulation for material removal in abrasive jet precision finishing with wheel as restraint

Abstract

The integration manufacturing technology is a kind of compound precision finishing process that combined grinding with abrasive jet finishing, in which inject slurry of abrasive and liquid solvent to grinding zone between grinding wheel and work surface under no radial feed condition when workpiece grinding were accomplished. The abrasive particles are driven and energized by the rotating grinding wheel and liquid hydrodynamic pressure and increased slurry speed between grinding wheel and work surface to achieve micro removal finishing. In the paper, the material removal rate (MRR) model in abrasive jet precision finishing with grinding wheel as restraint was investigated. When abrasive wore and workpiece surface micro-protrusion removed, the size ratio for characteristic particle size to minimum film thickness gradually diminishing, the abrasive machining from two-body lapping to three-body polishing transition in finishing with grinding wheel as restraint. Furthermore, the material removal rate model was established according to machining mechanisms and machining modes from two-body to three-body process transition condition, and active number of particles in grinding zone were calculated and simulated. Experiments were performed in the plane grinder for material removal mechanism and academic models verify. It can be observed from experimental results that the appearance of the surface change dramatically to a grooved or micro-machined surface with all the grooves aligned in the sliding direction in two-body lapping machining mode. On the other hand, the surface is very different, consists of a random machining pits with very little sign of any directionality to the deformation in the three-body machining mode. Consequently, the material removal rate model was found to give a good description of the experimental results.