| YAN Qiusheng,WANG Tao,HUANG Zhanliang,HUANG Bei,PAN Jisheng,CHEN Yuanjing,XIA Jiangnan.Simulation and Experimental Study on Optical Surface Wide Ribbon Wheel Magnetorheological Polishing of Sapphire[J],53(4):140-151 |
| Simulation and Experimental Study on Optical Surface Wide Ribbon Wheel Magnetorheological Polishing of Sapphire |
| Received:April 28, 2023 Revised:August 11, 2023 |
| View Full Text View/Add Comment Download reader |
| DOI：10.16490/j.cnki.issn.1001-3660.2024.04.013 |
| KeyWord:polishing ribbon sapphire Bingham fluid polishing wheel groove structure numerical calculation flow field |
| Author | Institution |
| YAN Qiusheng |
School of Electromechanical Engineering, Guangdong University of Technology, Guangzhou , China |
| WANG Tao |
School of Electromechanical Engineering, Guangdong University of Technology, Guangzhou , China |
| HUANG Zhanliang |
School of Electromechanical Engineering, Guangdong University of Technology, Guangzhou , China |
| HUANG Bei |
School of Electromechanical Engineering, Guangdong University of Technology, Guangzhou , China |
| PAN Jisheng |
School of Electromechanical Engineering, Guangdong University of Technology, Guangzhou , China |
| CHEN Yuanjing |
School of Electromechanical Engineering, Guangdong University of Technology, Guangzhou , China |
| XIA Jiangnan |
School of Electromechanical Engineering, Guangdong University of Technology, Guangzhou , China |
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| Abstract: |
| At present, the processing of smooth and non-destructive optical curved sapphire has problems of high cost and low efficiency. Magnetorheological polishing technology has advantages of real-time update of abrasives, non-wear polishing tools, easy computer control, stable removal function and controllable performance of magnetorheological microgrinding head, etc. and is suitable for polishing processing of various types of complex surfaces. In order to optimize the surface structure of the polishing wheel, increase the fixing force of the polishing wheel on the magnetorheological polishing pad, and improve the polishing effect, it is necessary to simulate the fluids of the magnetorheological polishing ribbon during processing. According to the actual processing process of the cylindrical wide ribbon magnetorheological polishing wheel, Solidworks was used to model the polishing wheel in three dimensions, and then the simulation software COMSOL was imported for multiphysics coupling simulation. A machining simulation model for controlling the fluid characteristics of magnetorheological polishing pad Bingham was established, and the effects of the surface structure of the three polishing wheels on the magnetic flux density mode, flow velocity and flow field pressure distribution in the surface processing area of the workpiece were analyzed. At the same time, the polishing effect of the three polishing wheels was experimentally explored, and the influence of the surface structure of the polishing wheel on the material removal rate and surface roughness after polishing was explored. The simulation results showed that the geometric structure on the surface of the polishing wheel had the characteristics of enhancing the magnetic flux density mode in the polishing area, increasing the fluid flow velocity and fluid pressure. Compared with the smooth wheel machining area, the magnetic flux density mode increased by 18.5%, the average flow rate of the flow field increased by 7%, the total surface pressure increased by 54.4%, and the shear force increased from 250 Pa to 850 Pa. The experimental results showed that the roughness Sa of the smooth wheel, horizontal bar wheel and spiral wheel reached 1.6, 1.57, 1.08 nm, respectively, the scratch depth decreases from 60 nm to 11 nm, 9 nm and 5.5 nm, and the material removal rate was 0.145, 0.155, and 0.22 mg/h, respectively. Compared with smooth wheels, polishing wheels with grooved structures had better surface quality and higher material removal rate after polishing, among which the polishing effect of spiral wheels was the best. The product result of the total pressure and velocity in the near wall area of the final polishing wheel had good consistency with the experimental removal rate of the polishing wheel, and the error was within 10%. The groove structure can improve the fixing effect of the polishing liquid on the surface of the polishing wheel, affect the flow field motion state of the workpiece surface, and enhance the force of the polishing pad on the surface of the workpiece. Compared with smooth and transverse groove polishing wheels, spiral groove polishing wheels have the highest polishing efficiency and the lowest surface roughness, which can effectively improve the polishing effect. |
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