目的 提升光学玻璃表面加工质量。方法 基于荷叶叶脉分支规律,利用迭代函数系统构建具备自相似分支特征的荷叶叶脉仿生微结构模型,并应用于聚氨酯抛光垫表面结构设计。通过计算流体动力学方法对比分析无微结构、同心圆微结构、复合微结构及仿生微结构抛光工具下磨粒分布行为。进一步考虑微结构形貌、有效磨粒数、磨粒接触力、轨迹特征等因素,建立适用于定点抛光的材料去除模型,并使用Matlab编程进行仿真模拟。最后对K9玻璃进行定点抛光实验,验证模型有效性。结果 仿真结果表明,荷叶叶脉仿生微结构在相同时间内能显著提高加工区域内磨粒浓度与分布均匀性。材料去除模拟结果表明,去除深度随径向载荷、主轴转速及磨料浓度提升而增加,其中转速影响最显著。实验结果表明,理论预测与实测数据误差在5.9%~11.2%之间,表面粗糙度最低可降至(0.052±0.004) μm,轮廓趋势与仿真结果一致。结论 所提出的荷叶叶脉仿生微结构抛光工具能有效改善磨粒分布,提高抛光均匀性与表面质量,且所建立的模型具备良好的预测能力。
Abstract
During the polishing process by small tools, material removal primarily relies on the friction between the free abrasive particles in the polishing solution and the workpiece surface under the combined action of the polishing tool and the external load, thereby achieving the removal of the processed surface layer. However, when the polishing tool operates at high speed, the abrasive particles often fail to distribute uniformly across the processing area, leading to uneven particle distribution in different regions and consequently affecting polishing quality and material removal efficiency. Traditional polishing tool surface microstructure designs are often relatively simple and unable to effectively address the issue of uneven abrasive particle distribution in the processing area, particularly at high speed, so this phenomenon becomes more pronounced. The work aims to employ biomimetic design to innovate the microstructure of polishing tools, so as to address the uneven distribution of abrasive particles during the polishing process and thereby enhance the surface processing quality of optical glass. Inspired by the material transport system of plant leaves, an iterative function system (IFS) was used to construct a biomimetic microstructure model of lotus leaf veins, which was then applied to the surface microstructure design of polyurethane polishing pads. The branching structure of lotus leaf veins exhibited unique self-similarity, with branch angles and lengths naturally optimized to minimize flow resistance and achieve efficient material transport. This structural characteristic was incorporated into the polishing tool design to enhance polishing uniformity by optimizing abrasive particle distribution. To validate the impact of lotus leaf vein-inspired microstructures on abrasive particle distribution in polishing solutions, computational fluid dynamics (CFD) methods were applied to compare and analyze the abrasive particle distribution behavior of four polishing tools with different microstructures in polishing solutions. Additionally, based on factors such as microstructure morphology, effective abrasive particle count, abrasive particle contact force, and abrasive particle movement trajectories, a material removal theoretical model was established and a fixed-point polishing contour was simulated through Matlab programming. The effects of three process parameters including normal load, spindle speed, and abrasive concentration on material removal depth were explored. To validate the accuracy of the theoretical model, K9 glass localized polishing experiments were conducted with three sets of different process parameters. Simulation results indicated that lotus leaf vein-inspired microstructures achieved slurry saturation concentration faster than other microstructures within a shorter timeframe and exhibited more uniform abrasive particle distribution within the processing area, significantly enhancing abrasive particle concentration and stability during the processing. The results of the material removal model analysis indicated that spindle speed had the greatest impact on material removal depth, followed by normal load, while abrasive concentration had the least impact on removal depth. Experimental results showed that lotus leaf vein-inspired microstructures not only effectively improved the uniformity of abrasive distribution but also significantly enhanced material removal efficiency. A comparison of simulation results with experimental data showed that the error range between theoretical predictions and measured data was between 5.9% and 11.2%, and surface roughness was significantly improved in experiments, with the optimal condition achieving a surface roughness of (0.052±0.004) μm. In summary, the lotus leaf vein-inspired microstructure not only effectively improves the distribution and transport properties of abrasive particles in the polishing solution but also significantly enhances polishing uniformity and surface quality. Additionally, the established material removal model demonstrates excellent predictive capability.
关键词
小磨头抛光 /
仿生结构 /
荷叶叶脉 /
磨粒分布 /
材料去除机理 /
抛光工具
Key words
small tool polishing /
biomimetic structure /
lotus leaf veins /
abrasive particle distribution /
material removal mechanism /
polishing tool
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基金
国家自然科学基金（51805044）; 中国博士后科学基金（2024M762450）; 陕西省自然科学基础研究计划（2025JC-YBMS-389）
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