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Experimental investigations on weak magnetization-enhanced force-rheological polishing of SiC mold

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Abstract

To investigate the influence of weak magnetization-enhanced force-rheological polishing (WMEFRP) parameters on the surface quality of a small aspheric SiC mold, a magnetic shear thickening fluid (MSTF) containing shear thickening fluid (STF), Al2O3 particles, and carbonyl iron powder particles was developed. Furthermore, the polishing characteristics and stability of the method were analyzed through rheological tests and magnetic field simulation. Orthogonal experiments were carried out on a small aspheric SiC mold using a five-axis machining center. The influence of spindle speed, polishing clearance, abrasive particle size, and other factors on material removal rate (MRR), surface morphology, surface roughness (SR), and subsurface damage (SSD) depth was explored. The results showed that MRR and SSD depth increased with spindle speed, whereas SR first decreased and then increased. Polishing clearance had a significant negative correlation effect on MRR, SR, and SSD depth, whereas abrasive particle size had a weak positive correlation effect on them. The parameter optimization method based on the multi-objective matrix was used to evaluate the influence weight of MRR, SR, and SSD depth on the orthogonal test results. The optimal scheme was determined as follows: the spindle speed was 720 rpm, the polishing gap was 0.5 mm, and the particle size was 3 μm. The verification test was carried out by using the optimal scheme. The results showed that the SR and SSD depths were considerably reduced, and the surface/subsurface quality was considerably improved. This evaluation method could meet the technical requirements of high efficiency and high surface/subsurface quality for the polishing of a small-aperture aspheric SiC mold.

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Funding

This work was supported by the National Natural Science Foundation of China (51975203), the Natural Science Foundation of Hunan Province (2021JJ30113), and the Science and Technology Innovation Project of Hunan Province (2021RC4069). Authors Dongdong Zhou, Xiangming Huang, Yang Ming, and Xiyang Li have received research support from 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

    Dongdong Zhou, Xiangming Huang, Yang Ming & Xiyang Li

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  1. Dongdong Zhou
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  2. Xiangming Huang
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  3. Yang Ming
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  4. Xiyang Li
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Contributions

Dongdong Zhou contributed to the study conception and design. Material preparation, data collection and analysis were performed by Yang Ming and Xiyang Li. The first draft of the manuscript was written by Dongdong and Xiangming Huang, 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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Zhou, D., Huang, X., Ming, Y. et al. Experimental investigations on weak magnetization-enhanced force-rheological polishing of SiC mold. Int J Adv Manuf Technol 127, 3497–3512 (2023). https://doi.org/10.1007/s00170-023-11606-8

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  • DOI: https://doi.org/10.1007/s00170-023-11606-8

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