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Erosion analysis and experimental research of gas-liquid-solid soft abrasive flow polishing based on cavitation effects

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Abstract

Traditional soft abrasive flow (SAF) polishing is limited by its low material removal rate and its applicability to large workpieces. To address this issue, an innovative technique of a cavitation-based gas-liquid-solid abrasive flow polishing (CGLSP) process is proposed. The energy generated from cavitation effects is employed to increase the kinetic energy of abrasive particles in the fluid flow and the random movement of abrasive particles near the surface. The CGLSP mechanism is first introduced, and then, the cavitation erosion characteristics and material removal mechanism of brittle-plastic materials during polishing are investigated using a coupling computational fluid dynamics model. The simulated results show that erosion of the workpiece surface mainly occurs in the spiral area of the polishing tool. Furthermore, the erosion rate and erosion depth increase with increasing cavitation intensity. Subsequently, polishing experiments are conducted to verify the validity of the CGLSP method. The polishing results are verified by scanning electron microscopy (SEM) images of the polished surface. After polishing with the CGLSP method, most of the surface irregularities, such as microcracks and massive structures, are removed. The experimental results demonstrate that controlled polishing with cavitation erosion and abrasion can achieve a much higher quality surface on a large workpiece.

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Data availability

The datasets and materials used or analyzed during the current study are available from the corresponding author on reasonable request.

Abbreviations

ρ v :

Vapor phase density

ρ 1 :

Liquid phase density

α v :

Vapor phase volume fraction

α 1 :

Liquid phase volume fraction

u :

Velocity vector

μ :

Dynamic velocity

F :

Reaction force of discrete particles relative to continuous phase in unit volume

t :

Time

F d :

Drag force

F other :

Force acting on particles

u p :

Particle velocity

g :

Gravitational acceleration

ρ p :

Particle density

ρ :

Water density

N :

Number of particles per unit time

m p :

Mass of the particle

v :

Impact velocity of the particle

μ 1 :

Dynamic viscosity

R b :

Radius of vacuole

R c :

Radius of condensation phase

R e :

Radius of evaporation phase

P ∞ :

Local pressure of the fluid

P b :

Bubble surface pressure

P :

Medium pressure in the flow field

P v :

Saturated vapor pressure of the medium

n b :

Number of bubbles in a unit liquid volume

v r :

Rebound velocity

v in :

Incoming velocity

e n :

Normal recovery coefficient

e t :

Tangential recovery coefficient

θ :

Impact angle

E(θ):

A unit of material volume removed per mass of particles

n 1, n 2 :

Exponents

s 1, s 2, q 1, q 2 :

Fitting constants

K :

Particle property factor

k 1, k 2 ,k 3 :

Exponent factors

R erosion :

Erosion rate

ER:

Erosion ratio

ρ w :

Density of the target surface materials

A face :

Erosion area

m :

Mass rate of particles impacting the cell surface

ERdepth :

Rate of the erosion depth

T :

A period of fixed-point processing

d :

Dwell point spacing

x 0 :

x-value

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Funding

This work was supported by the Natural Science Foundation of China under Grant Nos. 51775501 and 51575494, the Natural Science Foundation of Zhejiang Province under Grant No. LR16E050001.

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Authors and Affiliations

  1. College of Mechanical Engineering, Zhejiang University of Technology, Hangzhou, 310023, China

    Man Ge, Shiming Ji, Dapeng Tan & Huiqiang Cao

  2. Key Laboratory of Specially Purpose Equipment and Advanced Processing Technology, Ministry of Education and Zhejiang Province, Zhejiang University of Technology, Hangzhou, 310023, China

    Man Ge, Shiming Ji, Dapeng Tan & Huiqiang Cao

  3. Collaborative Innovation Center of High-End Laser Manufacturing Equipment (National “2011 Plan”), Zhejiang University of Technology, Hangzhou, 310023, China

    Dapeng Tan

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  1. Man Ge
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Contributions

Man Ge is responsible for methodology, investigation, software, writing, and editing. Shiming Ji and Dapeng Tan are responsible for funding support, algorithm implementation, supervision, and validation. Huiqiang Cao is responsible for methodology discussion and manuscript refinement.

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Correspondence to Dapeng Tan.

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Ge, M., Ji, S., Tan, D. et al. Erosion analysis and experimental research of gas-liquid-solid soft abrasive flow polishing based on cavitation effects. Int J Adv Manuf Technol 114, 3419–3436 (2021). https://doi.org/10.1007/s00170-021-06752-w

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