CFD-based study of the abrasive flow characteristics within constrained flow passage in polishing of complex titanium alloy surfaces

Zhang, Li; Yuan, Zhi-min; Qi, Zijian; Cai, Donghai; Cheng, Zhichao; Qi, Huan

doi:10.1016/j.powtec.2018.04.046

Cited by 45 publications

(13 citation statements)

References 30 publications

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“…Therefore, the realizable k-ε turbulence model is accepted in this paper to accurately predict the position and shape of the vortex and to predict the eddy tangent velocity and divergence ratio more accurately, so as to avoid distortion in the simulation analysis process. The Realizable k-ε model can be shown below [28]: (7) where…”

Section: Turbulent Equationmentioning

confidence: 99%

“…The sizes of abrasive particles must be strictly selected and controlled when the tool contact machining method is applied. Large-diameter abrasives always make the scratches of the processing object significantly deepened, which will eventually lead to a scrap of the workpiece [6][7]. Due to the restrictions of fluid-channel configurations and the pumping horsepower, the present SAF method is less efficient, particularly in the processing of intractable material [8][9].…”

Section: Introductionmentioning

confidence: 99%

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Numerical modelling and processing experiment of gas-liquid-solid three phase rotary abrasive flow machining

Tan¹,

Ni²,

Wu³

et al. 2022

Preprint

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Enhancing the processing efficiency and surface quality of difficult-to-machine materials such as large-area titaniferous alloy parts is the focus of low-carbon manufacturing. Here, we present a novel microbubble enhancement effect-based three-phase rotary abrasive flow polishing method (RGLSP). The characteristics of the high-speed rotary flow are calculated by the mixture model and modified realizable k-ε turbulence model. The simulation results reveal the dynamic characteristics of the high-speed turbulent vortex flow field formed by the three-phase abrasive flows in the constrained flow passages. The results show that the pitch-down angle of the processing medium inlet is the important parameter that affects the impact distribution features, and there is an optimal value for the impact characteristics of the rotary flow. Then the processing tool and RGLSP experimental platform are established, and the RGLSP method can improve the machining efficiency by 60%. The RGLSP method also can improve the surface quality of material without subsurface damage and the roughness can reach Ra 0.1µm after 150min machining.

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Section: Turbulent Equationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Numerical modelling and processing experiment of gas-liquid-solid three phase rotary abrasive flow machining

Tan¹,

Ni²,

Wu³

et al. 2022

Preprint

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“…The experiment proved that PLµP is an appropriate process that can improve the surface roughness of micro-milled Ti6Al4V. Li et al [ 26 ] proposed a novel constrained abrasive flow polishing technology. They introduced a triangular constraining plate to perform abrasive flow polishing on the surface of complex titanium alloys, which effectively improved the dimensional accuracy and surface quality.…”

Section: Introductionmentioning

confidence: 97%

Material Removal and Surface Integrity Analysis of Ti6Al4V Alloy after Polishing by Flexible Tools with Different Rigidity

Wang

et al. 2022

Materials

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Ti6Al4V alloy has been widely used in many fields, such as aerospace and medicine, due to its excellent biocompatibility and mechanical properties. Most high-performance components made of Ti6Al4V alloy usually need to be polished to produce their specific functional requirements. However, due to the material properties of Ti6Al4V, its polishing process still requires significant development. Therefore, this study aimed to investigate the performance of polishing Ti6Al4V by using tools with different rigidities. Two kinds of bonnet tool were used, namely a pure rubber (PR) bonnet and a semirigid (SR) bonnet. The characterization of material removal and surface integrity after polishing was conducted through a series of experiments on a 6-DOF robotic polishing device. The results demonstrate that both bonnet tools successfully produce nanometric level surface roughness. Moreover, the material removal rate of the SR bonnet tool is significantly higher than that of the PR bonnet, which is consistent with the material removal characteristics of glass polishing in previous research. In addition, the presented analysis on key polishing parameters and surface integrity lays the theoretical foundation for the polishing process of titanium alloy in different application fields.

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“…Sushil Mittal and other scholars designed the optimal parameter combination for the abrasive flow processing of aluminum-based SiC metal matrix composites [2]. Zhang L and other scholars discussed the study of the constrained abrasive flow precision machining of complex titanium alloys by numerical and experimental results, and found that the triangular restraint plate can greatly improve the efficiency and quality of precision machining [3]. Duval Chaneac and other scholars designed and fabricated clamp tubes and selective laser melting (SLM) components that can be disassembled and assembled during abrasive flow processing, and studied the surface roughness evolution on the inner surface of SLM components [4].…”

Section: Introductionmentioning

confidence: 99%

Numerical Analysis of Multi-Angle Precision Microcutting of a Single-Crystal Copper Surface Based on Molecular Dynamics

et al. 2022

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The molecular dynamics method was used to study the removal mechanism of boron nitride particles by multi-angle microcutting of single-crystal copper from the microscopic point of view. The mechanical properties and energy conversion characteristics of single-crystal copper during microcutting were analyzed and the atomic displacement and dislocation formation in the microcutting process are discussed. The research results showed that during the energy transfer between atoms during the microcutting process of boron nitride particles, the crystal lattice of the single-crystal copper atom in the cutting extrusion region was deformed and displaced, the atomic temperature and thermal motion in the contact area between boron nitride particles and Newtonian layer of workpiece increased, the single-crystal copper atom lattice was defective, and the atomic arrangement structure was destroyed and recombined. The interface of different crystal structures formed a dislocation structure and produced plastic deformation. With the increase of the impact cutting angle, the dislocation density inside the crystal increased, the defect structure increased and the surface quality of the workpiece decreased. To protect the internal structure of the workpiece and improve the material removal rate, a smaller cutting angle should be selected for the abrasive flow microcutting function, which can reduce the formation of an internal defect structure and effectively improve the quality of abrasive flow precision machining. The research conclusions can provide a theoretical basis and technical support for the development of precision abrasive flow processing technology.

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CFD-based study of the abrasive flow characteristics within constrained flow passage in polishing of complex titanium alloy surfaces

Cited by 45 publications

References 30 publications

Numerical modelling and processing experiment of gas-liquid-solid three phase rotary abrasive flow machining

Numerical modelling and processing experiment of gas-liquid-solid three phase rotary abrasive flow machining

Material Removal and Surface Integrity Analysis of Ti6Al4V Alloy after Polishing by Flexible Tools with Different Rigidity

Numerical Analysis of Multi-Angle Precision Microcutting of a Single-Crystal Copper Surface Based on Molecular Dynamics

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