Development of novel high-shear and low-pressure grinding tool with flexible composite

Tian, Yebing; Li, Linguang; Han, Jinguo; Fan, Zenghua; Liu, Kui

doi:10.1080/10426914.2020.1843673

Cited by 22 publications

(8 citation statements)

References 28 publications

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“…The polishing capability was better than traditional Newtonian fluid slurry because of the stress characteristics of shear thickening power-law fluid [17,18]. STFs and abrasive particles were evenly immersed into Kevlar fabrics bonding to the grinding wheel substrate to develop a novel high-shear and lowpressure grinding method [19][20][21]. Numerical simulation on the novel grinding process was implemented to verify the highshear and low-pressure effect [22].…”

Section: Introductionmentioning

confidence: 99%

Investigation on rheological characteristics of magnetorheological shear thickening fluids mixed with micro CBN abrasive particles

Qian¹,

Tian²,

Fan³

et al. 2022

Smart Mater. Struct.

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The novel magnetorheological shear thickening polishing fluids (MRSTPFs) were developed by mixing micro CBN abrasive particles into traditional magnetorheological shear thickening fluids (MRSTFs). MRSTPFs were constructed by uniformly fumed silica and polyethylene glycol as shear thickening fluids (STFs), carbonyl iron particles (CIPs) as ferromagnetic phase and cubic boron nitride particles (CBNs) as abrasive phase. In this work, various MRSTPFs were prepared to explore their rheological characteristics. Sweeps of steady shear rate and dynamic shear frequency were conducted under different magnetic flux densities, respectively. A mathematical model was presented to explain shear rate variation with shear stress. The magnetorheological shear thickening mechanism was well described. The rheological experiment results have revealed that shear thickening effect was still existing in magnetic flux density. However, the increased magnetic flux density played a negative role on the shear thickening effect. Particle size optimizationof CIPs was thus essential to maximize the shear thickening effect. On the other hand, with increased shear frequency, the viscoelastic feature of MRSTPFs was converted from linear to non-linear. It was found that the shear yield stress of the MRSTPFs was magnified with the stronger magnetic flux density and larger CIPs size. The investigation of rheological characteristics demonstrated that MRSTPFs could enhance polishing performance, which contributed to developing a high-efficiency and ultra-precision polishing process.

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Section: Introductionmentioning

confidence: 99%

Investigation on rheological characteristics of magnetorheological shear thickening fluids mixed with micro CBN abrasive particles

Qian¹,

Tian²,

Fan³

et al. 2022

Smart Mater. Struct.

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“…Nickel-based superalloys are widely employed in extreme environments to manufacture complex components in the aero-engine and gas turbine industries due to their high thermal stability, high corrosion resistance and high strength at elevated temperatures [1][2][3]. Grinding is the main material removal process currently used to achieve final dimensional accuracy, profile accuracy, and surface integrity for these safety critical industrial applications [4][5][6][7][8][9][10]. However, due to the complex thermo-mechanical interaction between the grinding tools and the workpiece, severe plastic deformation (SPD) always takes place in the superficial layer of the workpieces, usually leading to local alterations of the microstructure (e.g.…”

Section: Introductionmentioning

confidence: 99%

Creep feed grinding induced gradient microstructures in the superficial layer of turbine blade root of single crystal nickel-based superalloy

Miao

Ding

et al. 2021

Int. J. Extrem. Manuf.

102

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The service performance of the turbine blade root of an aero-engine depends on the microstructures in its superficial layer. This work investigated the surface deformation structures of turbine blade root of single crystal nickel-based superalloy produced under different creep feed grinding conditions. Gradient microstructures in the superficial layer were clarified and composed of a severely deformed layer (DFL) with nano-sized grains (48–67 nm) at the topmost surface, a DFL with submicron-sized grains (66–158 nm) and micron-sized laminated structures at the subsurface, and a dislocation accumulated layer extending to the bulk material. The formation of such gradient microstructures was found to be related to the graded variations in the plastic strain and strain rate induced in the creep feed grinding process, which were as high as 6.67 and 8.17 × 107 s−1, respectively. In the current study, the evolution of surface gradient microstructures was essentially a transition process from a coarse single crystal to nano-sized grains and, simultaneously, from one orientation of a single crystal to random orientations of polycrystals, during which the dislocation slips dominated the creep feed grinding induced microstructure deformation of single crystal nickel-based superalloy.

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“…Due to the improvement in requirements for material quality and surface accuracy within these industries, some difficult-to-process materials require further processing before they can be used. Grinding is the most widely used precision and ultra-precision processing technology, and is commonly employed in the aerospace industry, precision manufacturing and other fields [ 5 , 6 , 7 , 8 ]. Grinding is a multi-edge composite cutting technology.…”

Section: Introductionmentioning

confidence: 99%

“…In previous work [ 5 , 7 ], we used STF-Kevlar composite materials with abrasive grains to make a flexible grinding wheel. However, it was difficult to verify the grinding mechanism of the developed high-shear low-pressure flexible grinding wheel in experiments.…”

Section: Introductionmentioning

confidence: 99%

Simulation Analysis of Cluster Effect of High-Shear Low-Pressure Grinding with Flexible Abrasive Tools

et al. 2021

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Based on the clustering effect of shear-thickening fluids (STFs), a high-shear low-pressure flexible grinding wheel has been developed. In order to explore the material removal mechanism, the coupled Eulerian—Lagrangian (CEL) method is adopted to simulate the novel grinding process. The simulation results show that particle clustering effects do occur at the tangential and bottom positions of the micro-convex peak when it instantaneously strikes the workpiece surface. The particle clusters drive the harder abrasive particles to resist the strong interactions of micro-convex peaks. The micro-convex peaks are removed due to the cutting effect of the harder abrasive particles. Compared with traditional grinding, the ratio of tangential force to normal force for the high-shear low-pressure flexible grinding wheel is improved. The various trends in force ratio are consistent with the experimental results, which verifies the effectiveness of high-shear low-pressure grinding.

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Development of novel high-shear and low-pressure grinding tool with flexible composite

Cited by 22 publications

References 28 publications

Investigation on rheological characteristics of magnetorheological shear thickening fluids mixed with micro CBN abrasive particles

Investigation on rheological characteristics of magnetorheological shear thickening fluids mixed with micro CBN abrasive particles

Creep feed grinding induced gradient microstructures in the superficial layer of turbine blade root of single crystal nickel-based superalloy

Simulation Analysis of Cluster Effect of High-Shear Low-Pressure Grinding with Flexible Abrasive Tools

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