Abstract
A nanofinishing technique - Pneumatically Configurable Polishing (PCP) process can be used for producing surface roughness of the order of a few nanometers on surfaces. It is a deterministic polishing process which employs pneumatic pressure for precise control of finishing forces across the polishing spot. The material removal rate is an important characteristic for determining the final surface generated after polishing. The material removal mechanism of PCP process typically exhibits multidisciplinary complexity due to simultaneous contribution of various process parameters. A mathematical model has been proposed in this study to achieve an in-depth understanding of the process physics. The model is developed using the fundamental tenets of contact behaviour between the tool and workpiece, and study of the microscopic material removal caused by a single abrasive particle. The polishing tool undergoes a reciprocating linear feed to polish a linear strip of the work surface. Various process parameters such as feed rate, tool rotational speed, working gap, mean diameter of abrasive particles, slurry concentration etc have been incorporated in the model as per the physics of the process. In order to validate the model, finishing experiments and MATLAB simulations have been conducted under similar polishing conditions to estimate the prediction error. The material depth removal rate in the PC polishing of die steel was found to range between 39 nm/min and 257 nm/min. The error between the experimental and predicted values of material removal rate was found within a range of 2.7 %–15.9 %. The repeatability of final surface roughness values and MRR obtained is ±0.007 μm and ±10 nm/min respectively. The developed model helps to make the PCP process more predictable and provides valuable insights into the various parameters which predominantly affect the material removal. The simulation of the gradual evolution of the surface profile has been obtained using the developed model.
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