Abstract
Fluid jet polishing (FJP) is a non-contact polishing technology that can fabricate free-form optical surfaces with sub-micron-level form accuracy and nano-level surface roughness, especially for hard and brittle materials. The surface generation model of FJP can be used to guide the determination and optimization of process parameters and is of great significance for understanding the evolution mechanism of surface microtopography. However, predictive models for the microscopic topography of polished surfaces are still lacking. This study established a macroscopic surface profile model for predicting 3D material removal characteristics and surface texture by combining the 3D computer fluid dynamics (CFD) simulation model and single-particle erosion mechanism. A fractal theory-based erosion model has been built to calculate the material removal caused by the erosion of a single abrasive particle on the rough surface; thus, it predicts the micro-topography and surface roughness of the polished samples. A series of polishing experiments were conducted to analyze the feasibility and accuracy of the model quantitatively and study the influence mechanism of process parameters on the material removal characteristics and surface quality. Results indicated that the models could well predict material removal and surface roughness. The prediction accuracy of the surface roughness Ra and maximum removal depth is better than 91.6% and 90%, respectively. It is also found that the material removal rate of FJP could reach 0.517 mm3/min, and the surface roughness convergence rate could reach 62.9%.
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This work was supported by the National Natural Science Foundation of China (No. 51905376).
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Zhongchen CAO. He is associate professor at the School of Mechanical Engineering in Tianjin University. In 2016, he received his Ph.D. degree from the Department of Industrial and Systems Engineering in The Hong Kong Polytechnic University, and later worked as an assistant researcher and postdoctoral researcher in the State Key Laboratory of Ultraprecision Machining Technology in The Hong Kong Polytechnic University. His research interest is in the main following areas: ultra-precision free-form polishing and abrasive machining technology; material science/workpiece surface integrity analysis; modelling, simulation and optimization of manufacturing processes.
Ming WANG. He obtained the B.S. degree in mechanical engineering from Jilin University, Changchun, China, in 2021. Now he is a master student in Tianjin University, Tianjin, China. His research interest includes ultra-precision equipment design and processing.
Haitao LIU. He received the B.S., M.S., and Ph.D. degrees in mechanical engineering from Tianjin University, Tianjin, China, in 2004, 2007, and 2010, respectively. From 2013 to 2014, he stayed at the Chair of Mechanics and Robotics at University of Duisburg-Essen with a fellowship from the Alexander von Humboldt (AvH) Foundation of Germany. Currently he is professor in the School of Mechanical Engineering, Tianjin University. His research interests include robotics, kinematics and dynamics of parallel mechanisms, Lie group and Lie algebra, screw theory.
Tian HUANG. He is born in 1953, and currently a professor at Key Laboratory of Mechanism Theory and Equipment Design of Ministry of Education, Tianjin University, China.
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Cao, Z., Wang, M., Liu, H. et al. Modeling and analysis for material removal and surface roughness in fluid jet polishing of optical glass. Friction 12, 1548–1563 (2024). https://doi.org/10.1007/s40544-023-0832-9
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DOI: https://doi.org/10.1007/s40544-023-0832-9