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Material removal mechanism of fused silica glass in magnetorheological finishing

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Abstract

The existing material removal model of magnetorheological finishing cannot predict the material removal during part processing due to the problems of low processing efficiency, uniform removal, and difficulty in process control. In this paper, a new MRR (material removal rate) model is established to study the removal mechanism of fused silica glass based on the fluid mechanics and Preston’s equation, in which the influence of average load and magnetic interaction force is considered emphatically. To validate the validity of the MRR model, a suite of experiments is implemented on fused silica glass on separate process parameters, including the rotational speeds of workpieces, polishing time, machining gap, and X-direction deflection. A comparison is made between the experimental and model results, which are highly consistent. The results show that the expected load and magnetic interaction force are most responsive to the rotational speeds of the workpieces and machining gap, followed by the polishing time. At the same time, the X-direction deflection has marginal effects on the expected load and magnetic interaction force. Under irreversible experimental conditions of polishing time of 20 min, machining clearance of 2 mm, X-direction deflection of 10 mm, and workpiece rotation speed of 1000 rpm, the maximum MRR of the workpiece surface can be obtained as 0.497 μm/min.

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Abbreviations

MRR:

Material removal rate

P l :

The normal load on individual particle in Preston’s equation

P r :

Resultant pressure on workpiece in Preston’s equation

P :

Polishing pressure of micro-grinding head acting on workpiece surface

r 1 :

Distance from the center of magnetic pole to the boundary of polishing (buffing) disc

P d :

Fluid dynamic pressure on workpiece surface

P m :

Pressure exerted on the surface of a workpiece by a gradient magnetic field

P M :

Force of interaction between magnetic grain

N CIP :

Number of active carbonyl iron particle

N Chain :

Number of active chain

N M :

Number of active particle

N :

Number of effective abrasive grain

n p :

Number of pressing points

V s :

Relative velocity between workpiece and polishing disc

A p :

Area of polishing area

A e :

The surface area of the workpiece

E :

Young’s modulus

P :

Polishing pressure

k v :

Compressibility of MR fluids

K :

Preston coefficient

k c :

Fracture toughness of the workpiece

H V :

Hardness of workpiece

L m, c :

Average particle size of loaded grain

Z :

Machining gap between the workpiece and the polishing disc

△r/r :

The relationship between radial strains

V :

Volume of cylindrical micro-grinding head

V Z :

Total volume of abrasives in the polishing discs

ε:

Radial stress

\({\sigma}_{r_1}\) :

Stress of hardened magnetorheological fluid on workpiece

B :

Magnetic flux density

H :

Magnetic field strength of workpiece surface

Φ:

Magnetic flux

Φ0 :

Total magnetic flux on the magnetic pole surface

Φa :

Axial magnetic flux of magnetorheological fluid

f :

The radial magnetic flux density

Z 1 :

Thickness of polishing film

M :

Magnetization of carbonyl iron powder

M f :

Magnetization of the entire magnetic field

χm :

The polarization coefficient of the entire magnetic field

β:

Magnetic susceptibility of carbonyl iron powder

ω1 :

Rotational speeds of workpieces

ω2 :

Rotational speeds of buffing disc

e :

Rotation eccentricities of magnetic poles

h e :

Film thickness function

h 0 :

Film thickness at the maximum point of pressure

ηN :

Newtonian fluid viscosity coefficient

ηt :

Viscosity coefficient of pseudoplastic fluid

η:

Working viscosity of the magnetorheological fluid

ΦCIP :

Mass fraction of carbonyl iron powder in clustered magnetorheological finishing fluid

ΦM :

Mass fraction of abrasive in clustered magnetorheological finishing fluid

Φ:

Volume ratio of magnetic grain

μ:

Magnetic permeability of carbonyl iron powder

R 3 :

The distance between particles

μ0 :

Permeability of vacuum

μr :

Relative permeability of magnetic media

μp :

Magnetic permeability of the carrier fluid

μ1 :

Magnetic permeability of the magnetic particle

R :

Distance from the center of the disc to the center of the magnetic pole

R W :

Radius of workpiece

r 1 :

Single polishing pad radius; polishing head radius

ρC :

Density of carbonyl iron powder

ρM :

Powder density of cerium oxide

d CIP :

Particle size of carbonyl iron powder

d M :

Abrasive particle size

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Funding

This work was supported by the Jilin Province Science and Technology Development Key Project (20200401109GX), Jilin Province Micro-Nano and Ultra-Precision Manufacturing Key Laboratory (20140622008JC), Changchun Science and Technology Development Plan Project (21zgg08).

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Authors and Affiliations

  1. Key Laboratory of Micro-Nano and Ultra-Precision Manufacturing of Jilin Province, School of Mechatronic Engineering, Changchun University of Technology, Changchun, 130012, People’s Republic of China

    Limin Zhang, Weixing Li, Mingming Lu, Jieqiong Lin, Yuyang Liu & Changqing Liu

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  1. Limin Zhang
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  2. Weixing Li
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Contributions

Weixing Li: investigation, methodology, validation, writing—original draft, writing—review and editing; Limin Zhang: methodology, validation, experiments, writing—original draft, writing—review and editing; Mingming Lu: writing—review and editing; Jinqiong Lin: writing—review and editing; Yuyang Liu: software, data curation; Changqing Liu: software, data curation.

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Correspondence to Mingming Lu.

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Zhang, L., Li, W., Lu, M. et al. Material removal mechanism of fused silica glass in magnetorheological finishing. Int J Adv Manuf Technol 128, 1271–1289 (2023). https://doi.org/10.1007/s00170-023-11970-5

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