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Modeling of tool influence function for the abrasive cloth flap wheel and optimization of polishing path spacing and feed rate

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Abstract

In order to use abrasive tools more effectively, it is important to understand their working capability. As a complex, fully-compliant abrasive polishing tool, the tool influence function (TIF) of the abrasive cloth flap wheel (ACFW) has not been studied and modeled. Experimental testing and data analysis was conducted to analyze the variations in the shape of the TIF, maximum material removal depth, material removal volume, and the average offset of the TIF with key process parameters for dry and wet polishing. A TIF experimental model for ACFW polishing was developed using cubic polynomial surface fitting and coefficient regression. Further, based on the principle of curvilinear integration, the cross-sectional profile of single-line polishing with various relative feed angles is accurately simulated, and the influence of the micro-topography in the TIF on the simulation results is discussed. Moreover, a method is proposed for the optimal selection of polishing path spacing and feed rate. Based on the established TIF model and single-line polished section profile calculation, cumulative removal profile simulations and parameter calculation with different polishing line spacing are carried out to select the combination of parameters with the maximum polishing efficiency within the constraints of material removal depth and its uniformity. The results of the validation experiments show that around the optimal parameter combination, the simulated profile follows the same trend as the peak-to-valley (PV) value of the measured profile, and the relative error between the cumulative material removal depth and the target value does not exceed 5%. These research findings establish a foundation and guidance for the more efficient utilization of the ACFW abrasive tool.

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Data availability

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

Abbreviations

TIF:

Tool influence function

ACFW:

Abrasive cloth flap wheel

PV:

Peak-to-valley

TPR_error:

Tool path ripple error

MRV:

Material removal volume

MRD:

Material removal depth

RMSE:

Root mean squared error

MCS:

Measuring coordinate system

WLCS:

Workpiece local coordinate system

MRA:

Material removal amount

TPS:

Tool path spacing

CRD:

Cumulative removal depth

k :

Preston coefficient

p :

Pressure at the contact position

v :

Relative polishing velocity at the contact position

t :

Polishing time

n :

Rotation speed

R N :

Nominal radius of the ACFW

R n :

Radius of the ACFW with rotation speed n

R c :

Normal distance between the axis of ACFW and the workpiece surface

Δs :

Compression amount of the ACFW

δ x :

Spacing of the point cloud in the x directions

δ y :

Spacing of the point cloud in the y directions

ε :

Threshold value used to exclude unpolished points

t d :

Dwell time of the experimental test

θ :

Angle between the direction of the tool axis and the direction of feed

v f :

Feed rate

ΔH :

Polishing allowance left by the previous process

W s :

Width of profile

η :

Threshold of PV value

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Acknowledgements

The authors deeply acknowledge the Key Laboratory of High Performance Manufacturing for Aero Engine (North-western Polytechnical University) and Engineering Research Center of Advanced Manufacturing Technology for Aero Engine (North-western Polytechnical University) for providing us with the ability to conduct this research.

Funding

This work was supported by the National Science and Technology Major Project of China [No. 2017-VII-0001–0095] and the National Natural Science Foundation of China [No. 51675439].

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Authors and Affiliations

  1. Key Laboratory of High Performance Manufacturing for Aero Engine, Ministry of Industry and Information Technology, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, People’s Republic of China

    Yun Zhang, Xiaojun Lin & Yaoyao Shi

  2. Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Ministry of Education, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, People’s Republic of China

    Yun Zhang, Xiaojun Lin & Yaoyao Shi

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  1. Yun Zhang
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Contributions

Conceptualization: X.L. and Y.S. Methodology: Y.Z. Investigation and data analysis: Y.Z. Writing-original draft preparation: Y.Z. Writing-review and editing: X.L. Funding acquisition: Y.S., X.L.

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Correspondence to Yun Zhang.

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Appendix 1

Appendix 1

Tables 5, 6

Table 5 TIF model for dry polishing
Full size table
Table 6 TIF model for wet polishing
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Zhang, Y., Lin, X. & Shi, Y. Modeling of tool influence function for the abrasive cloth flap wheel and optimization of polishing path spacing and feed rate. Int J Adv Manuf Technol 130, 683–704 (2024). https://doi.org/10.1007/s00170-023-12737-8

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