Optimization and experimental research on process parameters of the softness consolidation abrasive particles

Abstract

SCA (softness consolidation abrasive) finishing is a new type of machining method. The dilatancy effect of abrasive particles during processing causes the local accumulation of abrasives particles and leads to scratches on the surface of the workpiece, which in the meantime decreases finishing efficiency. So, microscopic contact mechanic model of abrasive particles is established to analyze the force chain transfer phenomenon. A microscope constitutive model of abrasive particles is established to reflect the microscopic force-displacement relationship between abrasive particles. The force chains net evolution of the abrasive particles with different porosity and the surface stress distribution of workpieces are simulated by PFC3D.The results show that when the porosity exceeds 44%, the internal force chain transmission path of the abrasive particles disappears; the surface stress of workpieces exhibits a periodic distribution. As the porosity increases, the stress amplitude decreases. Finally, the test platform is set up and the laws of porosity and abrasive’s size on surface roughness of workpieces can be concluded after a series of polishing experiments by pneumatic wheels with softness consolidation abrasive. The experiments results show that when the abrasive’s size is 800 and the porosity is 24%, the surface roughness of workpieces is small, and the surface average roughness of workpieces can decrease from 313.744 to 67.11 nm.