Estimation of Temperature Levels in the Area of Polishing with Polymer-Abrasive Brushes

Abstract

A technique for measuring and monitoring the temperature in the area of processing with polymer-abrasive (PA) brush tools of rotary action, which have thermal performance limitations due to the low melting temperature of the fiber polymer base, is proposed. There is very contradictory information, which has been obtained mostly theoretically, about temperature level in the working area when polishing with PA brushes. Therefore, experimental thermal studies directly in the “brush-sample” contact zone are relevant. It is important for maintaining high tool-life of brush PA tools. The temperature in the processing zone is influenced by the polishing modes (feed, tension, speed), tool parameters (diameter and length of fibers, which characterize the brush stiffness). The samples were made of different materials (steel 3, aluminum AM12 and titanium VT8-M alloys) in order to evaluate the effect of thermal conductivity on the temperature in the processing area. It was found that the temperatures measured during processing without lubricant-cooling agents were 30…130 °C depending on modes and brush rigidity. The dependence of the maximum temperatures in the “contact patch” on the modes and parameters of the tool when polishing with brushes of various materials was established. Most PA brushes have a thermal limit of 100…120 °C. Most polishing work can be done without lubricant-cooling agents. However, to work on “hard” modes or on materials with low thermal conductivity it is necessary to apply lubricant-cooling agents or brushes with high thermal resistance of fibers (200 °C); such brushes have recently appeared on the market of tools for finishing operations.