Electrorheological (ER) polishing as a new type of polishing technique has flexibility and controllability. However, ER polishing cannot be widely used in actual processing because the present ER polishing fluid is usually prepared by simple mixing abrasive materials into ER fluid, which is easy to occur phase separation and decreased ER performance. This paper develops a new type of ER polishing material based on cerium-doped titanium dioxide. As a classic abrasive, the cerium oxide not only has high polishing performance but also can enhance ER performance of titanium dioxide by doping effect, which endows the cerium-doped titanium dioxide with high ER polishing efficiency compared to ER polishing fluid prepared by a simple mixing method. Cerium-doped titanium dioxide particles were prepared by the sol-gel method. The size, surface morphology and elemental distribution were characterized. The ER properties were tested. The effects of different concentrations, machining gap, voltage and rotation speed on polishing performance were studied. Under the conditions of a 0.2 mm machining gap, 3 kV voltage and 200 r/min rotation speed, the surface roughness (Ra) of the copper workpiece decrease from 136 nm to 14.4 nm after 0.5 h of polishing, which is far higher than the polishing efficiency of simple mixed ER polishing fluid.
Electrorheological (ER) polishing is a novel polishing technology having flexible and tunable characteristics. At present, ER polishing uses ER particles to drive abrasive particles to polish the material surface. Under the action of high-speed centrifugation, the abrasive particles are easily separated from ER particles due to their significantly different ER effect, and this can easily cause the degradation of polishing ability. In this work, alumina-doped titanium dioxide ER polishing particles were developed via a sol-gel method. As a classical abrasive, alumina has higher hardness and can improve the ER effect of titanium dioxide by doping. Thus, alumina-doped titanium dioxide particles simultaneously possess high ER effect and high hardness. No phase separation appears in the polishing process and the result shows that alumina-doped titanium dioxide has a good polishing efficiency for materials with Mohs hardness of 3 and below.
In this study, we reported a kind of hollow poly(ionic liquid)/α-Al2O3 composite particles prepared by rapid microwave-assisted Pickering emulsion polymerization using the commercial high hardness α-Al2O3 abrasive (Mohs hardness = 9) as a particulate surfactant. The structure and morphology were characterized by different techniques. The as-prepared composite particles were then used as the dispersed phase of the electrorheological polishing fluid. Our results demonstrated that the hollow poly(ionic liquid) core provided dispersion stability and electrorheological effect, while the α-Al2O3 shell provided high hardness and polishing capability. Under an electric voltage of 3 kV, the polishing fluid of the hollow poly(ionic liquid)/α-Al2O3 composite particles could improve the surface quality of the stainless-steel workpiece with Mohs hardness of 5 from Ra ∼270 to ∼90 nm. This polishing performance was extraordinary and far better when compared to that of the polishing fluid consisting of a simple mixture of poly(ionic liquid) particles and α-Al2O3 particles. During polishing, the voltage, rotation speed, working gap, and polishing time were demonstrated to have an effect on polishing efficiency. This study paves the way to develop electrorheological polishing fluids with dispersion stability and high polishing efficiency by combining hollow polymer particles and high hardness of abrasives.
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