Numerical and experimental investigation into tool-workpiece interaction in flexible abrasive tool finishing

Abstract

The present work examines the finishing performance of oxygen-free high conductivity (OFHC) copper using a fabricated flexible abrasive tool. It is challenging to finish soft materials like copper and aluminium using traditional finishing techniques due to frequent scratching. Flexible finishing tool can protect the surface integrity of the workpiece samples during finishing action. Flexible abrasive tools are fabricated using solvent casting method. This method fabricates the flexible tools with homogeneous abrasive dispersion and an open-cell porous structure. The developed tool is self-sharpening and self-lubricating and can finish soft materials efficiently. The flexible abrasive tools can be fabricated in different shapes and sizes to finish internal features and complex shapes. The interaction between the tool and workpiece is examined by the forces exerted by the flexible tool on the workpiece. The areal surface roughness of the finished surface is reduced to 33 nm from its initial roughness of 937 nm after 20 min of finishing a pre-defined region. Theoretical analysis is carried out to estimate contact pressure using Hertz contact theory. The results obtained from numerical and theoretical analysis have a close correlation with the experimental results. The maximum deviation of peak contact pressure obtained in theoretical estimation and numerical analysis from experimental results is found to be 20.73 % and 12.83 %, respectively. As the model includes the basic physics of the tool-workpiece interaction, the results can be improved with the inclusion of micro-level analysis of fluid-filled flexible abrasive tools with embedded abrasives.