Solid-liquid Two-phase Abrasive Flow Research Articles

Experimental and Numerical Analysis of the Assisted Abrasive Flow of Magnetic Particles on the Polishing of Fuel Injection Nozzles

Fuel injection nozzles are a key component of electronic injection engines, and their inner surface roughness affects the performance of the nozzles and restricts the working efficiency of the engine. Therefore, the polishing technology for a nozzle’s inner surface is particularly important. At present, abrasive flow polishing technology is commonly used to treat the inner surfaces of the nozzles. This study investigated the magnetic particles in the abrasive flow working medium. Due to the external magnetic field, magnetic particles are affected by the magnetic field force and change the polishing performance of the abrasive flow working medium. Through a numerical analysis and contrast experimental research, we can see that the choice of different grinding grain sizes, kinematic viscosity, magnetic field intensity, and process parameters, such as inlet pressure, with magnetic particles in a solid–liquid two-phase abrasive flow for polishing, can effectively improve the quality of the injection nozzle’s inner surface. The study also reveals that the influence of the nozzle’s inner surface polishing quality is significant and creates a mechanism for process parameters.

Research on quality control of precision machining straight internal gear by abrasive flow based on large eddy simulation

Traditional finishing technology is difficult to realize the precision machining of complex geometric parts. Abrasive flow machining technology solves this problem well. Taking the spur internal gear as the research object, the wall shear force, static pressure, dynamic pressure, and abrasive velocity vector of the internal channel of the straight internal gear under different inlet velocity, abrasive concentration, and abrasive particle size are analyzed by using the large eddy simulation method, and the action law of different parameters on the machining of straight internal gear by solid–liquid two-phase abrasive flow is discussed. At the same time, the orthogonal test was carried out. The results show that the solid–liquid two-phase abrasive flow machining technology can effectively remove the burrs, pits, and bulges on the tooth surface of spur internal gear, reduce the tooth surface roughness, and improve the surface quality. The optimal combination of processing parameters and the primary and secondary order of various factors affecting processing are obtained by range analysis and analysis of variance. The regression equation is constructed by regression analysis to verify the effectiveness and accuracy of the model, which provides theoretical support and data reference for actual processing and production.

Research on quality analysis of solid-liquid two-phase abrasive flow precision machining based on different sub-grid scale models

Research on quality analysis of solid-liquid two-phase abrasive flow precision machining based on different sub-grid scale models

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

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.

Optimisation design and analysis of variable‐diameter pipe parameters for solid–liquid two‐phase abrasive flow processing

To study the quality control technology and process specifications of solid–liquid two-phase abrasive flow research and development, the fourth-order variable diameter pipe is taken as the research object, and then the quality control method of abrasive flow polishing variable diameter pipe is established. Through the analysis of the abrasive flow of the fourth-order variable-diameter pipe, it is known that the surface texture of the variable-diameter pipe becomes smoother and denser after the grinding flow, and the surface roughness Ra of the variable-diameter pipe is reduced from the original 1.469 μm to after polishing 0.295 μm, the surface roughness is improved, and the ideal polishing quality is obtained. Under the experimental conditions, the optimal process parameters of solid–liquid two-phase abrasive flow were obtained, and the regression model of surface roughness and process parameters was established, which provided technology for engineering application of solid–liquid two-phase abrasive flow.

Numerical simulation analysis of four‐stage variable diameter pipe for solid–liquid two‐phase abrasive flow

By exploring the effects of energy and velocity under different inlet speeds and abrasive concentrations, different inlet boundary conditions were selected for numerical analysis, and the intrinsic properties of the solid–liquid two-phase abrasive flow research and development calibre pipes were explored. The influence of law and process characteristics of solid–liquid two-phase abrasive flow is discussed. The fourth-order variable diameter pipe is taken as the research object. It is concluded that the inlet velocity is increased, the total energy and kinetic energy of the abrasive grains are also increased, and the total energy and kinetic energy are increased. The more intensely the abrasive grains collide with the workpiece wall, the more favourable is the effect of the abrasive flow on the wall surface finishing, and the increase of the abrasive concentration. The number of collisions of the disordered abrasive grains on the wall surface is increased, which is more conducive to the wall surface. The finishing process provides theoretical reference and technical support for the engineering application of solid–liquid two-phase abrasive flow.

Numerical simulation research on s-shaped elbows polished by abrasive flow based on large eddy simulation

To predict and improve the surface quality of complex curved surface structure precision machined by solid-liquid two-phase abrasive flow, this paper takes the S-shaped elbow as the research object, carries out the numerical simulation of abrasive flow polishing process of S-shaped elbow based on large eddy simulation method, analyzes the velocity distribution of abrasive flow, turbulent energy, wall shear force nephogram and trace diagram of abrasive flow in the S-shaped elbow under different inlet speed and abrasive concentration conditions. It is found that the values of velocity, turbulent energy and wall shear force on the inner side of the elbow and the outlet pipe are relatively large, indicating that the polishing quality at these positions is better. Increasing the inlet velocity can improve the effectiveness of abrasive flow polishing, and properly increasing the abrasive concentration can improve the surface uniformity of polished wall. It can provide a theoretical basis for promoting the continuous improvement of abrasive flow precision machining technology.

Mechanism Research and Discussion of the Quality of Precision Machining of a Fifth-order Variable-diameter Pipe Using Abrasive Flow

The solid-liquid two-phase abrasive flow precision machining technology is widely used in aerospace, precision machinery, the automotive industry and other fields, and is an advanced manufacturing technology that effectively improves the inner surface quality of workpieces. In this paper, the fifth-order variable-diameter pipe parts are researched. By discussing the collision between the abrasive particles and the wall surface, it is revealed that the material removal of the workpiece is caused by plastic deformation, and the mechanism of precision machining of the abrasive flow is clarified. Through numerical analysis and experimental research, it is found that the incident angle can affect the precision machining quality of the abrasive flow. When the inlet velocity of the abrasive flow is 45 m/s and the incident angle is 15°, the fifth-order variable-diameter pipe can obtain the best surface quality. Abrasive flow machining improves the surface quality of small holes better than that of large holes. To obtain uniform surface quality, it is necessary to use two-way machining to perform abrasive flow machining. The surface texture of the fifth-order variable-diameter pipe workpiece after precision machining by abrasive flow becomes clear and smooth, and the surface quality is significantly improved. The research results can provide theoretical guidance and technical support for the popularization and application of solid-liquid two-phase abrasive flow precision machining technology, with significant academic value and application value.

Study on the surface forming mechanism of the solid–liquid two-phase grinding fluid polishing pipe based on large eddy simulation

To study the surface forming mechanism of the solid–liquid two-phase abrasive flow processing, the large eddy simulation method was used. Taking a 90° stainless steel elbow as the research object, the action mechanism of the dynamic pressure, wall shear force, flow state of the abrasive flow at different cross-sections, formation of the vortex, and trajectory of the abrasive flow on the inner surface of the elbow with abrasive flow composed of solid-phase silicon carbide and liquid-phase hydraulic oil are discussed. This study explores the distribution characteristics of the flow pattern of solid–liquid two-phase abrasive flow. Moreover, the wear and erosion of the abrasive grain and the wall of the workpiece are discussed. The mechanism of surface formation of solid–liquid two-phase abrasive flow is revealed.

Numerical analysis of the influence of abrasive concentration on the quality of baffle servo valve in abrasive flow machining

In order to analyze the effect of abrasive concentration on the quality of abrasive flow machining, this paper takes the baffle servo valve as the research object and carries out numerical analysis of solid-liquid two-phase abrasive flow machining process. By analyzing the static pressure and velocity fields of nozzle orifices in baffle servo valves under different abrasive concentration conditions, it is found that abrasive flow has the best precision machining effect when the abrasive concentration is 10 %. And the best quality area for abrasive flow machining is in the small hole. The study shows that the larger the abrasive concentration is, the better the quality of abrasive flow machining is.

Numerical Analysis of Solid-Liquid Two-Phase Abrasive Flow in Microcutting Polycrystalline Materials Based on Molecular Dynamics

Abrasive flow polishing plays an important role as a type of precision nanomachining technology. In this study, the polishing mechanism of abrasive flow was studied using numerical simulations based on molecular dynamics. In order to study the polishing mechanism of polycrystalline materials, the molecular dynamics simulation of three kinds of polycrystalline materials was carried out. The cutting force, energy, friction coefficient, and surface morphology (during the microcutting process) of the three workpiece materials were analyzed. The analysis shows that the adhesion of atoms in the contact area on the workpiece surface will be affected by liquid phase and the type of abrasive particles, and then the surface quality polished by the abrasive flow will also be influenced. The onset of an abrasive flow polishing process involving plastic deformation (including the nucleation and migration of dislocations, grain boundary shape deformation, and deformation twinning) was observed on the workpiece surface. Defects strongly competed with each other in the form of interactions of dislocations and the grain boundaries, resulting in the migration of twin boundaries. A further analysis of the numerical results for different cutting depths and abrasive properties of the workpiece materials will be useful for understanding the different cutting effects.

Study on whole factorial experiment of polishing the micro-hole in non-linear tubes by abrasive flow

It is generally observed that special channels exit in many key components of machine, such as non-linear tube, applied in military or civil industries. Its surface finish is a crucial factor in the whole performance of machine. In military and civil fields, many key parts have special passages, such as non-linear tube. The surface quality of non-linear tube usually decides the general using property of the whole equipment. The abrasive flow machining technology can effectively improve the surface quality of non-linear tube parts and promote the using property of the whole equipment. The technology of solid-liquid two-phase abrasive flow machining can obtain higher enhancement in surface quality. To investigate the processing technology of abrasive flow machining for non-linear tube–injection nozzle, we performed a full factorial experiment modifying critical process parameters such as particle density, particle size, and abrasive viscosity during the machining. The study investigated the relationship among abrasive particle physical property, surface quality of non-linear tube, and the optimal parameters. At the same time, we deduced the regression equation which takes the abrasive particle physical property as the key factor. Through full factorial experimental study, it is found that under the experimental conditions of this article, abrasive flow polishing process serves best when the abrasive concentration is 10% and the particle size is 6 μm. Moreover, the verification experiment of the non-linear nozzle is carried out. The average value of the experimental data is located in the prediction interval, which confirmed the accuracy of the whole factor test. The experimental results can provide technical support for further research of abrasive flow machining theory. The research results in this article have profound theoretical significance and practical value for improving the machining efficiency of non-linear parts and obtaining high-quality-surface passages. The study data possess important theory significance and practical value for improving the processing efficiency for non-linear tube and obtaining a high-quality surface channel. The experimental results can provide technology support for further study on abrasive flow machining theory.

Numerical Study on Abrasive Flow of the Fuel Spray Nozzle Based on RNG k-ε Model

In view of the current problems that it is difficult to polish small size and complex curved surface, a processing method based on solid-liquid two-phase abrasive flow is proposed. In order to verify the rationality and practicability of the processing method, the numerical simulation is carried out for the processing of solid-liquid two-phase abrasive flow. By using the RNG k-ε turbulence model and the Mixture model, the fuel spray nozzle is taken as the research object. The dynamic pressure, the turbulent dissipation rate and turbulent kinetic energy at the nozzle hole are analyzed and compared. The simulation results show that with the increase of inlet velocity, dynamic pressure, fluid velocity and turbulent kinetic energy at nozzle orifice increase at some extent, which tells that the effect of solid-liquid two-phase flow on the pore wall is stronger, the more intense the friction between the fluid and the wall, the better the polishing effect, thus the effectiveness of the abrasive flow processing was concluded and providing theoretical support for the fluid processing of complex components.

Numerical Simulation Analysis of Five-Step Variable-Diameter Pipe with Solid-Liquid Two-Phase Abrasive Flow Polishing

In many areas of precision machining abrasive flow polishing technology has an important role. In order to study the influence of abrasive flow on the polishing effect of variable diameter parts, the fifth step variable diameter tube was taken as the research object to analyze the dynamic pressure and turbulent kinetic energy distribution of inlet velocity on the fifth-order variable diameter tube influences. Through comparative analysis, the abrasive flow polished variable diameter pipe parts have very effective and significant polishing effect and the higher the inlet speed, the more significant the polishing effect.

Numerical analysis of spiral curved tube of the solid liquid two phase abrasive flow polishing

In order to solve the problem that the inner surface of heterosexual surface parts is difficult to be machined, a solid-liquid two-phase abrasive flow machining method is proposed. The standard model and the pressure-coupled SIMPLEC algorithm are used. The dynamic characteristics of the dynamic pressure, turbulent kinetic energy and turbulence intensity of the polygonal spiral surface flow channel were obtained by numerical analysis of the solid-liquid two-phase abrasive grain polished polygonal spiral curved pipe under different outlet pressure conditions. The numerical simulation results show that the grinding effect is inversely proportional to the outlet pressure. We can achieve better polishing effect by appropriately reducing the outlet pressure.

Numerical simulation analysis of valve spool double-nozzle with abrasive flow

In order to study the numerical simulation of abrasive flow polishing small hole parts, the servo valve spool double nozzle parts were used as the research object, and the solid-liquid two-phase abrasive flow were used for numerical simulation, getting the dynamic pressure, velocity cloud and turbulent kinetic energy of the abrasive flow are obtained at different inlet velocities. Through the comparative analysis, the effect of the process parameters on the effect of the abrasive flow polishing small hole parts was obtained, which can provide a theoretical basis for the continuous improvement of the ultra-precision machining technology to promote the abrasive flow, so that the fatigue strength of the workpiece is improved, the reliability of the workpiece is enhanced and its service life is prolonged.

Numerical simulation analysis of large eddy simulation for T-tube based on solid-liquid two-phase abrasive flow

As a kind of nano machining technology, abrasive flow polishing technology plays an important role in precision machining region. As an important numerical simulation method in fluid mechanics, large eddy numerical simulation method has become an important method for many scholars to study abrasive grain polishing technology. In this paper, the use of fluid mechanics software FLUENT and selected Mixture mixed model. Based on the theory of solid-liquid two-phase flow dynamics, the large-eddy numerical simulation method was used to study the polishing process of T-tube abrasive flow, and the micro-machining mechanism of abrasive-polished workpiece was discussed. The influence of the different inlet velocities on the polishing effect of the abrasive grains was discussed by analyzing the numerical simulation results of the different inlet velocities of the abrasive grains during the processing of the T-tube.

Numerical analysis and experimental study on micro-holes in solid-liquid two-phase abrasive flow machining

In order to solve the problem that the aperture of the small hole part is too small and the irregular shape of the surface is difficult to be processed. A solid - liquid two - phase abrasive grain polishing method is proposed. Based on the standard model and SIMPLEC algorithm, the numerical simulation of the surface of the micro – holes were carried out under different inlet speed conditions. The change of the turbulence kinetic energy, dynamic pressure and turbulence intensity of the micro – holes flow channel with the inlet velocity is discussed. The quality control law of the inlet velocity on the sol-id-liquid two-phase abrasive flow polishing. In order to verify the accuracy of the numerical analysis, the necessary solid-liquid two-phase flow polishing test was carried out with the micro-hole parts. The surface roughness of the inner surface of the micro-holes before and after polishing was tested. The results show that the surface roughness is reduced from 1.702 before polishing to 0.303 after polishing. The solid - liquid two - phase abrasive flow machining can effectively improve the surface quality of micro – holes.

Numerical analysis in viscosity-temperature characteristics of solid-liquid two-phase abrasive flow polishing

The non-linear tube is widely used in military and civil fields and the general performance of the machine depends on the internal channel surface quality of it. The effective ways to improving the surface quality is solid-liquid two-phase abrasive flow polishing technology. So, the numerical analysis about the internal channel of non-linear tube polished by abrasive flow is implemented to analyze the effect of viscosity-temperature characteristics of abrasive flow polishing on the internal channel surface quality. Turbulent kinetic energy, intensity and viscosity, nephogram of the dynamic pressure distribution, and corresponding relation of temperature and turbulent kinetic energy, near the wall of non-linear tube, are received from the simulation in different initial turbulent kinetic energy and temperature which provides a theoretical basis for controlling the surface quality.

Quality influence and process parameter optimization of T-pipe in abrasive flow finishing

In order to study the effect of solid–liquid two-phase abrasive flow on the surface of inner wall of the special-shaped cavity and relationship between finishing parameters and surface quality, the...