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Research on prediction method of surface roughness in weak magnetorheological shear thickening fluid polishing

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Abstract

A joint prediction method of “mathematical modeling and finite element calculation” is proposed to improve the prediction of machining quality in weak magnetorheological shear thickening fluid polishing of complex surfaces. The study proceeded in several steps. First, based on both impact energy model and material removal model, a numerical prediction model of surface roughness is established. Second, based on the multi-peak fitting method, the field-induced rheological properties of the polishing fluid are characterized and material properties of the flow field medium in the polishing zone are defined. Third, the numerical boundaries of polishing flow velocity and shear stress in the above prediction model are obtained. Fourth, the polishing experiments with parameters consistent with the above simulation model are conducted, and the initial surface roughness values are substituted into the above prediction model. The results show that the joint prediction method can effectively predict the machining quality of workpiece surface. The absolute error of Sa value of surface roughness is up to 10.6 nm, and the maximum relative error is 12.3%.

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Funding

This work was supported in part by the Natural Science Foundation of China (NSFC, contract grant numbers: 51975203), Natural Science Foundation of Hunan Province (2021JJ30113), and Science and Technology Innovation Project of Hunan Province (2021RC4069). Authors Yang Ming, Xiangming Huang, Cai Yunhui, and Zhou Dongdong have received research support from Company Hunan University, College of Mechanical and Vehicle Engineering.

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Authors and Affiliations

  1. College of Mechanical and Vehicle Engineering, Hunan University, Changsha, 410082, China

    Yang Ming, Xiangming Huang, Yunhui Cai & Dongdong Zhou

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  1. Yang Ming
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  2. Xiangming Huang
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  3. Yunhui Cai
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  4. Dongdong Zhou
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Contributions

All authors contributed to the study conception and design. Material preparation, data collection, and analysis were performed by Yunhui, Cai, and Dongdong, Zhou. The first draft of the manuscript was written by Y. Ming, and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Xiangming Huang.

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Ming, Y., Huang, X., Cai, Y. et al. Research on prediction method of surface roughness in weak magnetorheological shear thickening fluid polishing. Int J Adv Manuf Technol 124, 2659–2673 (2023). https://doi.org/10.1007/s00170-022-10668-4

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  • DOI: https://doi.org/10.1007/s00170-022-10668-4

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