Quality research and prediction of six-order variable-diameter pipe processed by solid-liquid two-phase magnetic abrasive flow

Abstract

Abrasive flow machining, as a precision machining method to improve surface roughness by material removal, has advantages that traditional techniques cannot match. In order to obtain a sixth-order variable-diameter pipe with excellent service performance, a new solid-liquid two-phase magnetic abrasive flow polishing method is adopted in this paper. The influence of inlet speed, magnetic field strength, and abrasive particle size on machining quality is investigated by numerical simulation and orthogonal experiment. The simulation results show that adding and increasing the magnetic field is beneficial to the machining. Besides, the simulation results show that the wall shear stress increases with the increase of inlet speed and abrasive particle size, which can improve the machining effect. Based on the simulation, the orthogonal experiment with three factors and three levels is carried out, and the minimum surface roughness can reach 0.054 μm. Based on the analysis of the roughness test results, the best combination of processing parameters is obtained. The regression equation between the polishing parameters and roughness is established, which provides technical guidance and quality prediction for the future processing by solid-liquid two-phase magnetic abrasive flow.