Removal of millimeter-scale rolled edges using bevel-cut-like tool influence function in magnetorheological jet polishing.

Abstract

Subaperture polishing techniques usually produce rolled edges due to edge effect. The rolled edges, especially those in millimeter scale on small components, are difficult to eliminate using conventional polishing methods. Magnetorheological jet polishing (MJP) offers the possibility of the removal of these structures, owing to its small tool influence function (TIF) size. Hence, we investigate the removal characters of inclined MJP jetting models by means of computational fluid dynamics (CFD) simulations and polishing experiments. A discrete phase model (DPM) is introduced in the simulation to get the influence of abrasive particle concentration on the removal mechanism. Therefore, a more accurate model for MJP removal mechanisms is built. With several critical problems solved, a small bevel-cut-like TIF (B-TIF), which has fine acentric and unimodal characteristics, is obtained through inclined jetting. The B-TIF proves to have little edge effect and is applied in surface polishing of thin rolled edges. Finally, the RMS of the experimental section profile converges from 10.5nm to 1.4nm, and the rolled edges are successfully suppressed. Consequently, it is validated that the B-TIF has remarkable ability in the removal of millimeter-scale rolled edges.