The work aims to develop a novel magnetic compound fluid (MCF) polishing tool incorporating porous carbonyl iron powder (PCIP) to investigate the role of porous structures in moisture retention and abrasive distribution optimization within MCF, thereby addressing issues of performance degradation and increased costs caused by water loss during polishing, which currently restricts MCF applications. Firstly, porous carbonyl iron powder was prepared through a pitting corrosion method. XRD, SEM, BET, and VSM techniques were employed to investigate the effects of reaction time on material structure, micromorphology, pore size, and magnetic properties of PCIP. Afterwards, polishing experiments were conducted with a stylus profilometer to examine the effect of PCIP-containing MCF on workpiece surface roughness and material removal rate during polishing. Finally, by establishing the intrinsic relationships among polishing quality, polishing force, MCF morphological state, wettability, and polishing temperature, the moisture retention mechanism of PCIP and the impact of porous structures on abrasive distribution were explored. Experimental results demonstrated that by controlling the reaction time, porous structures with different pore sizes could be fabricated on the surface of carbonyl iron powder. Within 3 hours, as the reaction time prolonged, the pore size and specific surface area of PCIP (porous carbonyl iron powder) gradually increased, while its magnetic properties correspondingly decreased. However, the structure of the carbonyl iron powder remained unchanged throughout this process. The polishing effect of MCF2 containing PCIP-2 was the best. After 60 min of polishing, the surface roughness of the workpiece decreased from 337 nm to 22 nm, with a reduction rate of about 93.5%, which was 4.9% higher compared to MCF0 (containing carbonyl iron powder without a porous structure), and the material removal rate increased from 4.36×108 μm3/min to 6.65×108 μm3/min. The positive pressure of MCF0 and MCF1 both decreased slowly with the increase of polishing time, and finally reached 4.8 N and 4.6 N respectively. The positive pressure of MCF2 reached a stable stage earlier and finally stabilized at 5.2 N. The positive pressure generated by MCF3 was relatively small, at 2.5 N. The shear forces of MCF0 to MCF3 after 10 minutes of polishing were 0.59 N, 0.89 N, 0.44 N and 0.11 N respectively. The morphology of MCF2 after polishing was well maintained, PCIP-2 powder showed better hydrophilicity, and the temperature rise in the polishing area was smaller. The contact angles of PCIP-0 to PCIP-3 were 94.21°, 29.86°, 20.52° and 118.32°, respectively. The temperature rises at three points of MCF2 were 3.1 ℃, 3.2 ℃ and 2.5 ℃, respectively. Compared with the other three MCFs, the temperature rise of MCF2 was lower. The overall temperature rise of the polishing area was 3 ℃. The temperature rises of MCF0, MCF1 and MCF3 were 3.6 ℃, 3.3 ℃ and 4.5 ℃, respectively. The order of temperature rise was MCF2<MCF1<MCF0<MCF3, and the final surface temperature of the workpiece after polishing with MCF2 was the lowest. The fluid storage and sustained-release properties of the porous structure maintains the lubrication and cooling effect during polishing and extends the service life of the polishing fluid. The distribution of abrasive particles is optimized through embedding, fixation and other methods, which improves the polishing performance of MCF.
Key words
magnetic compound fluid /
surface roughness /
material removal rate /
polishing performance /
porous carbonyl iron powder /
TC4 titanium alloy
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Funding
National Natural Science Foundation of China (52265056, 52262013); Natural Science Foundation of Gansu Province (23JRRA776); Special Project for Central Government-Guided Local Science and Technology Development in Sichuan Province (2024ZYD0260); Lanzhou Youth Talent Project (2023-QN-38)
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