Analytical model of dynamic and overlapped footprints in abrasive air jet polishing of optical glass

Zhao, Wenli; Li, Hao Nan; Yu, Tianbiao; Wang, Zi Xuan; Zhao, Ji

doi:10.1016/j.ijmachtools.2019.03.005

Cited by 34 publications

(6 citation statements)

References 62 publications

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“…Two-thousand abrasives with size of 15-120 µm were used as the solid phase, which was simulated by a discrete phase model. The boundary conditions and governing equations can be found in [36][37][38][39][40][41][42]. A MATLAB script was employed to analyze the simulation results for the impact location, frequency, velocity, and velocity loss of the abrasives.…”

Section: Cfd Simulation Setupmentioning

confidence: 99%

“…Milling and shape-adaptive grinding are frequently chosen for processing the external surface; however, their application is constrained by the intricate shape of the part. Electropolishing, electrochemical-mechanical polishing (ECMP) [27][28][29][30], magnetic abrasive finishing (MAF) [31][32][33], multi-jet hydrodynamic finishing (MJHF) [34], and abrasive flow finishing (AFF) [35,36] are usually applied to polish and smooth interior channels. Zhao et al [29] and An et al [30] proposed to polish the L-PBF fabricated channel with different diameters via an ECMP process.…”

Section: Introductionmentioning

confidence: 99%

“…Recent studies have employed abrasive air jet (AAJ) and multi-phase jet (MPJ) polishing to improve the Sa of rigid and brittle materials [36][37][38][39]. Wang et al [36,37] optimized AAJ polishing parameters by utilizing a low jet pressure, small jet angle, and small-sized abrasives. This optimization led to a minimum Sa of 0.244 µm while polishing quartz glass.…”

Section: Introductionmentioning

confidence: 99%

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A novel approach of jet polishing for interior surface of small-grooved components using three developed setups

Gu,

Zhang,

Zhou

et al. 2024

Int. J. Extrem. Manuf.

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It is a challenge to polish the interior surface of an additively manufactured component with complex structures and groove sizes less than 1 mm. Traditional polishing methods are disabled to polish the component, meanwhile keeping the structure intact. To overcome this challenge, small grooved components made of aluminum alloy with sizes less than 1 mm were fabricated by a custom-made printer. A novel approach of multi-phase jet polishing is proposed using a developed polisher, consisting of solid, liquid and gas phases. In comparison, an abrasive air jet polishing is suggested through a customized polisher, including solid and gas phases. After jet polishing, surface roughness (Sa) on the interior surface of grooves decreases from pristine 8.596 to 0.701 and 0.336 μm by abrasive air jet polishing and multi-phase jet polishing, respectively, and Sa reduces 92% and 96%, correspondingly. A formula is given out for the relationship between linear energy density and unit defect volume. The optimized parameters in additive manufacturing are that linear energy density varies from 0.135 to 0.22 J∙mm-1. Defect volume of unit area achieved by optimized parameters lessens 1/12 that of non-optimized ones. Computational fluid dynamics simulation reveals that material is removed by shear stress, and the alumina abrasives experience multiple collisions with the defects on the heat pipe groove, resulting in uniform material removal. This is in good agreement with the experimental results. The novel proposed setups, approach and findings provide new insights to manufacture complex-structured components, polish the small grooved structure, and keep it unbroken.

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Section: Cfd Simulation Setupmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

A novel approach of jet polishing for interior surface of small-grooved components using three developed setups

Gu,

Zhang,

Zhou

et al. 2024

Int. J. Extrem. Manuf.

View full text Add to dashboard Cite

show abstract

“…Therefore, some nontraditional processing methods have been used, such as ultrasonic machining, laser beam machining, and abrasive flow machining. Nonetheless, nontraditional machining methods are ineffective in resolving problems such as microcracks in glass micromachining, thereby limiting their widespread use in this field [ 5 , 6 , 7 , 8 , 9 , 10 ]. In a previous study, a new composite machining method, electrochemical discharge machining (ECDM), was proposed to improve the processing quality.…”

Section: Introductionmentioning

confidence: 99%

Study of Gas Film Characteristics in Electrochemical Discharge Machining and Their Effects on Discharge Energy Distribution

Liu

Adayi

2023

Micromachines

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Glass is a hard and brittle insulating material that is widely used in optics, biomedicine, and microelectromechanical systems. The electrochemical discharge process, which involves an effective microfabrication technology for insulating hard and brittle materials, can be used to perform effective microstructural processing on glass. The gas film is the most important medium in this process, and its quality is an important factor in the formation of good surface microstructures. This study focuses on the gas film properties and their influence on the discharge energy distribution. In this study, a complete factorial design of experiments (DOE) was used, with three factors and three levels of voltage, duty cycle, and frequency as the influencing factors and gas film thickness as the response for the experimental study, to obtain the best combination of process parameters that would result in the best gas film quality. In addition, experiments and simulations of microhole processing on two types of glass, quartz glass and K9 optical glass, were conducted for the first time to characterize the discharge energy distribution of the gas film based on the radial overcut, depth-to-diameter ratio, and roundness error, and to analyze the gas film characteristics and their effects on the discharge energy distribution. The experimental results demonstrated the optimal combination of process parameters, at a voltage of 50 V, a frequency of 20 kHz and a duty cycle of 80%, that achieved a better gas film quality and a more uniform discharge energy distribution. A thin and stable gas film with a thickness of 189 μm was obtained with the optimal combination of parameters, which was 149 μm less than the extreme combination of parameters (60 V, 25 kHz, 60%). These studies resulted in an 81 μm reduction in radial overcut, a roundness error reduced by 14, and a 49% increase in the depth–shallow ratio for a microhole machined on quartz glass.

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“…The solid particle impact model is mainly used to study the erosion wear mechanism during abrasive cutting or to predict the influence of multiple particles on the surface morphology of the target workpiece 5,6 . Wang suggests an analytical model of the polished surface topography (or footprint) considering the horizontally asymmetric cross‐section profiles of a single‐abrasive impact footprint and the abrasive‐workpiece elastic deformation and further springback when the abrasive bounces back 7 . Slikkerveer derives relations for the parameters from the basic indentation models that are important for an industrial process: erosion rate, surface roughness and strength 8 .…”

Section: Introductionmentioning

confidence: 99%

Study on abrasive particle impact modeling and cutting mechanism

Lin

Zhang

et al. 2021

Energy Science & Engineering

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Abrasive water jet impact is widely applied in processing, oil fracturing, coal mining, rock crushing, and other engineering fields. The influence of abrasive particles on cutting performance is one of the main characteristics of this technology, which is different from pure fluid cutting. Therefore, as for improving the cutting performance of abrasive water jet, studying the cutting mechanism of abrasive water jet, and clarifying the mapping relationship between particle parameters and cutting, it is of great theoretical and practical significance to clarify the impact failure mechanism and material removal mechanism of abrasive particles in the process of high‐speed impact. In order to study the effect of abrasive particles on cutting performance, irregular abrasive particles are simplified to angular particles and circular particles in this paper. The impact shooting process of particles in abrasive jet cutting is numerically simulated by using smoothed particle hydrodynamics (SPH) method, and the target impact experiments are carried out. The fracture processes of ductile materials and brittle targets impacted by different shapes of particles are studied. The results are showed as follows. Firstly, the SPH numerical model has high accuracy and successfully reproduces the collision process of particles in the process of abrasive jet cutting, including the deformation mechanisms such as plowing, cracking and crushing of the target, and the error of the dent curve formed by the collision is less than 0.5 mm. Secondly, the impact mechanism of angular and circular particles is different for targets with different material properties. For ductile materials, the process of material accumulating to failure value is slow, mainly by the way of accumulation removal. And for brittle materials, it mainly produces plastic deformation and failure, without obvious material accumulation and extrusion area. Thirdly, different impact angles of particles have great influence on material removal.

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Analytical model of dynamic and overlapped footprints in abrasive air jet polishing of optical glass

Cited by 34 publications

References 62 publications

A novel approach of jet polishing for interior surface of small-grooved components using three developed setups

A novel approach of jet polishing for interior surface of small-grooved components using three developed setups

Study of Gas Film Characteristics in Electrochemical Discharge Machining and Their Effects on Discharge Energy Distribution

Study on abrasive particle impact modeling and cutting mechanism

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