The primary determinant of microfluidic chip performance is the surface quality of the micro-tapered holes.Due to the small scale of these holes and the high hardness of the surface attachments,the commonly used abras...The primary determinant of microfluidic chip performance is the surface quality of the micro-tapered holes.Due to the small scale of these holes and the high hardness of the surface attachments,the commonly used abrasive jet polishing method can encounter difficulties.Therefore,we propose a novel active multiphase field material removal technique.This technique is based on piezoelectric ultrasonically coupled abrasive particle flow.To study the connection between the impulse properties of the flow field and the micro-tapered hole’s asymptotic expansion–contraction process,a multiphase hybrid fluid dynamics model is established.Simultaneously,we investigate the process of abrasive–wall contact during the cycles of expansion and contraction,revealing the effects of erosion and polishing on different areas of the hole surface.To achieve accurate regulation of a desired polishing area,a quantitative relationship between the vibrational properties of piezoelectric ceramics and the erosional effect of micro-tapered holes is established.Finally,an experimental platform for micro-tapered hole polishing is built to validate the method.展开更多
Soft abrasive flow（SAF） finishing can process the irregular geometric surfaces, but with the matter of low processing efficiency. To address the issue, an improved SAF finishing method based on turbulent kinetic ene...Soft abrasive flow（SAF） finishing can process the irregular geometric surfaces, but with the matter of low processing efficiency. To address the issue, an improved SAF finishing method based on turbulent kinetic energy enhancing is proposed. A constrained flow passage with serration cross-section is constructed to increase the turbulence intensity. Taking the constrained flow passage as the objective, a two-phase fluid dynamic model is set up by using particle trajectory model and standard k-ε turbulence model, and the flow field characteristics of the flow passage are acquired. The numerical results show that the serration flow passage can enhance the turbulence intensity, uniform the particles distribution, and increase the particle concentration near the bottom wall. The observation results by particle image velocimetry（PIV） show that the internal vortex structures are formed in flow passage, and the abrasive flow takes on turbulence concentrating phenomenon in near-wall region. The finishing experiments prove that the proposed method can obtain better surface uniformity, and the processing efficiency can be improved more 35%. This research provides an abrasive flow modeling method to reveal the particle motion regulars, and canoffer references to the technical optimization of fluid-based precision processing.展开更多
The investigation was carried out on the technical problems of finishing the inner surface of elbow parts and the action mechanism of particles in elbow precision machining by abrasive flow.This work was analyzed and ...The investigation was carried out on the technical problems of finishing the inner surface of elbow parts and the action mechanism of particles in elbow precision machining by abrasive flow.This work was analyzed and researched by combining theory,numerical and experimental methods.The direct simulation Monte Carlo(DSMC)method and the finite element analysis method were combined to reveal the random collision of particles during the precision machining of abrasive flow.Under different inlet velocity,volume fraction and abrasive particle size,the dynamic pressure and turbulence flow energy of abrasive flow in elbow were analyzed,and the machining mechanism of particles on the wall and the influence of different machining parameters on the precision machining quality of abrasive flow were obtained.The test results show the order of the influence of different parameters on the quality of abrasive flow precision machining and establish the optimal process parameters.The results of the surface morphology before and after the precision machining of the inner surface of the elbow are discussed,and the surface roughness Ra value is reduced from 1.125μm to 0.295μm after the precision machining of the abrasive flow.The application of DSMC method provides special insights for the development of abrasive flow technology.展开更多
Lower surface roughness and sharper cutting edge are beneficial for improving the machining quality of the cut?ting tool, while coatings often deteriorate them. Focusing on the diamond coated WC?Co milling cutter, the...Lower surface roughness and sharper cutting edge are beneficial for improving the machining quality of the cut?ting tool, while coatings often deteriorate them. Focusing on the diamond coated WC?Co milling cutter, the abrasive flow machining(AFM) is selected for reducing the surface roughness and sharpening the cutting edge. Comparative cutting tests are conducted on di erent types of coated cutters before and after AFM, as well as uncoated WC?Co one, demonstrating that the boron?doped microcrystalline and undoped fine?grained composite diamond coated cutter after the AFM(AFM?BDM?UFGCD) is a good choice for the finish milling of the 6063 Al alloy in the present case, because it shows favorable machining quality close to the uncoated one, but much prolonged tool lifetime. Besides, compared with the micro?sized diamond films, it is much more convenient and e cient to finish the BDM?UFGCD coated cutter covered by nano?sized diamond grains, and resharpen its cutting edge by the AFM, owing to the lower initial surface roughness and hardness. Moreover, the boron incorporation and micro?sized grains in the underly?ing layer can enhance the film?substrate adhesion, avoid the rapid film removal in the machining process, and thus maximize the tool life(1040 m, four times more than the uncoated one). In general, the AFM is firstly proposed and discussed for post?processing the diamond coated complicated cutting tools, which is proved to be feasible for improving the cutting performance展开更多
The polishing efficiency of the soft abrasive flow(SAF)method is low,which is not in line with the concept of carbon emission reduction in industrial production.To address the above issue,a two-phase fluid multi-physi...The polishing efficiency of the soft abrasive flow(SAF)method is low,which is not in line with the concept of carbon emission reduction in industrial production.To address the above issue,a two-phase fluid multi-physics modeling method for ultrasonic-assisted SAF processing is proposed.The acoustics-fluid coupling mechanic model based on the realizable k-ε model and Helmholtz equation is built to analyze the cavitation effect.The results show that the pro-posed modeling and solution method oriented to ultrasonic-assisted SAF processing have better revealed the flow field evolution mechanism.The turbulence kinetic energy at different ultrasonic frequencies and amplitudes is stud-ied.Simulation results show that the ultrasonic vibration can induce a cavitation effect in the constrained flow chan-nel and promote the turbulence intensity and uniformity of the abrasive flow.A set of comparative polishing experiments with or without ultrasonic vibration are conducted to explore the performance of the proposed method.It can be found that the ultrasonic-assisted SAF method can improve the machining efficiency and uniformity,to achieve the purpose of carbon emission reduction.The relevant result can offer a helpful reference for the SAF method.展开更多
This paper reviews recent developments of the soft abrasive flow finishing(SAF)method in constraint space.The multiphase fluid dynamics modeling,material removal mechanism,auxiliary strengthening finishing techniques,...This paper reviews recent developments of the soft abrasive flow finishing(SAF)method in constraint space.The multiphase fluid dynamics modeling,material removal mechanism,auxiliary strengthening finishing techniques,and observation of surface impact effects by abrasive particles and cavitation bubbles are presented in brief.Development prospects and challenges are given for four aspects:thin-walled curved surfaces,biomedical functions,electronic information,and precise optical components.展开更多
Aiming at the problem of difficult contact finishing for mini structural surface in course of mould manufacturing,a new no-tool precision machining method based on soft abrasive flow machining(SAFM)was proposed.It all...Aiming at the problem of difficult contact finishing for mini structural surface in course of mould manufacturing,a new no-tool precision machining method based on soft abrasive flow machining(SAFM)was proposed.It allocated restrained component near surface machined,constituted restrained abrasive flow passage,and made the surface become a segment of passage wall.It could control turbulence abrasive flow in restrained passage,realize micro cutting for passage wall,and utilize the irregular motion of abrasive flow to eliminate the mono-directional marks on machined surfaces,and the precision could reach the specular level.A two-phase dynamic model of abrasive flow oriented to SAFM combined with discrete phase model(DPM)was established,the law of two-phase flow motion and the related physical parameters was obtained by corresponding numerical simulation method,and the mechanism of precision machining in SAFM was discussed.Simulation results show that the abrasive flow machining process mainly appears as translation of ablating location with the influence by granular pressure,and as the variation of machining efficiency with the influence by near-wall particle velocity.Thus via control of the inlet velocity and its corresponding machining time,it is supposed to work out the machining process according to the machining requirements by using the Preston equation to seek the relationship among velocity,pressure and material removing rate.By tracking near-wall particles,it can be confirmed that the movement of near-wall abrasive particles is similar to stream-wise vortices.The cutting traces on workpiece surfaces assume disorderly arrangement,so the feasibility of the SAFM method can be reaffirmed.展开更多
Improvement of surface finish and material removal has been quite a challenge in a finishing operation such as abrasive flow machining （AFM）. Factors that affect the surface finish and material removal are media vis...Improvement of surface finish and material removal has been quite a challenge in a finishing operation such as abrasive flow machining （AFM）. Factors that affect the surface finish and material removal are media viscosity, extrusion pressure, piston velocity, and particle size in abrasive flow machining process. Performing experiments for all the parameters and accurately obtaining an optimized parameter in a short time are difficult to accomplish because the operation requires a precise finish. Computational fluid dynamics （CFD） simulation was employed to accurately determine optimum parameters. In the current work, a 2D model was designed, and the flow analysis, force calculation, and material removal prediction were performed and compared with the available experi- mental data. Another 3D model for a swaging die finishing using AFM was simulated at different viscosities of the media to study the effects on the controlling parameters. A CFD simulation was performed by using commercially available ANSYS FLUENT. Two phases were considered for the flow analysis, and multiphase mixture model was taken into account. The fluid was considered to be a Newtonian fluid and the flow laminar with no wall slip.展开更多
Inconel 718 superalloy has extensive applications in a variety of industries such as the moulding,aerospace and medical due to its excellent mechanical features such as poor thermal conductivity,high strength at high ...Inconel 718 superalloy has extensive applications in a variety of industries such as the moulding,aerospace and medical due to its excellent mechanical features such as poor thermal conductivity,high strength at high temperatures and corrosion resistance.However,it is very difficult to process by traditional machining and finishing methods.Abrasive based finishing process is one of non-traditional finishing method applied to complex surfaces.Shot peening process is one of the surface treatment processes mostly applied to improve the surface strength.The superior advantages of these two processes are combined into one process.This newly developed and patented process is called as GOV process.In this study,the effects of GOV process parameters(number of cycles,steel ball size,media concentration)on the surface quality of Inconel 718 already pre-processed by wire electric discharge machining are investigated.The performance parameters are identified as surface roughness,material removal and white layer thickness.Surface finishing with the GOV process improves the surface roughness,Ra value by decreasing from 2.63μm to 0.46μm by removing micro-level chips up to 10.7 mg which is supported by SEM images.White layer formed due to nature of EDM process is completely removed from specimen surface.展开更多
基金supported by the National Natural Science Foundation of China(Nos.U25A20294,52175124,52575546,and 52305139)the Zhejiang Provincial Natural Science Foundation of China(Nos.LQ23E050017 and LZ21E050003)+1 种基金the Fundamental Research Funds for the Provincial Universities of Zhejiang,China(No.RF-A2024001)the China Postdoctoral Science Foundation(No.2025M771342).
文摘The primary determinant of microfluidic chip performance is the surface quality of the micro-tapered holes.Due to the small scale of these holes and the high hardness of the surface attachments,the commonly used abrasive jet polishing method can encounter difficulties.Therefore,we propose a novel active multiphase field material removal technique.This technique is based on piezoelectric ultrasonically coupled abrasive particle flow.To study the connection between the impulse properties of the flow field and the micro-tapered hole’s asymptotic expansion–contraction process,a multiphase hybrid fluid dynamics model is established.Simultaneously,we investigate the process of abrasive–wall contact during the cycles of expansion and contraction,revealing the effects of erosion and polishing on different areas of the hole surface.To achieve accurate regulation of a desired polishing area,a quantitative relationship between the vibrational properties of piezoelectric ceramics and the erosional effect of micro-tapered holes is established.Finally,an experimental platform for micro-tapered hole polishing is built to validate the method.
基金Supported by National Natural Science Foundation of China(Grant Nos.51375446,51575494)Zhejiang Provincial Natural Science Foundation of China(Grant Nos.LR16E050001,LZ14E050001)
文摘Soft abrasive flow（SAF） finishing can process the irregular geometric surfaces, but with the matter of low processing efficiency. To address the issue, an improved SAF finishing method based on turbulent kinetic energy enhancing is proposed. A constrained flow passage with serration cross-section is constructed to increase the turbulence intensity. Taking the constrained flow passage as the objective, a two-phase fluid dynamic model is set up by using particle trajectory model and standard k-ε turbulence model, and the flow field characteristics of the flow passage are acquired. The numerical results show that the serration flow passage can enhance the turbulence intensity, uniform the particles distribution, and increase the particle concentration near the bottom wall. The observation results by particle image velocimetry（PIV） show that the internal vortex structures are formed in flow passage, and the abrasive flow takes on turbulence concentrating phenomenon in near-wall region. The finishing experiments prove that the proposed method can obtain better surface uniformity, and the processing efficiency can be improved more 35%. This research provides an abrasive flow modeling method to reveal the particle motion regulars, and canoffer references to the technical optimization of fluid-based precision processing.
基金Projects(51206011,U1937201)supported by the National Natural Science Foundation of ChinaProject(20200301040RQ)supported by the Science and Technology Development Program of Jilin Province,China+1 种基金Project(JJKH20190541KJ)supported by the Education Department of Jilin Province,ChinaProject(18DY017)supported by Changchun Science and Technology Program of Changchun City,China。
文摘The investigation was carried out on the technical problems of finishing the inner surface of elbow parts and the action mechanism of particles in elbow precision machining by abrasive flow.This work was analyzed and researched by combining theory,numerical and experimental methods.The direct simulation Monte Carlo(DSMC)method and the finite element analysis method were combined to reveal the random collision of particles during the precision machining of abrasive flow.Under different inlet velocity,volume fraction and abrasive particle size,the dynamic pressure and turbulence flow energy of abrasive flow in elbow were analyzed,and the machining mechanism of particles on the wall and the influence of different machining parameters on the precision machining quality of abrasive flow were obtained.The test results show the order of the influence of different parameters on the quality of abrasive flow precision machining and establish the optimal process parameters.The results of the surface morphology before and after the precision machining of the inner surface of the elbow are discussed,and the surface roughness Ra value is reduced from 1.125μm to 0.295μm after the precision machining of the abrasive flow.The application of DSMC method provides special insights for the development of abrasive flow technology.
基金Supported by National Natural Science Foundation of China(Grant No.51275302)China Postdoctoral Science Foundation Special Funded Project(Grant No.2016T90370)China Postdoctoral Science Foundation(Grant No.2015M580327)
文摘Lower surface roughness and sharper cutting edge are beneficial for improving the machining quality of the cut?ting tool, while coatings often deteriorate them. Focusing on the diamond coated WC?Co milling cutter, the abrasive flow machining(AFM) is selected for reducing the surface roughness and sharpening the cutting edge. Comparative cutting tests are conducted on di erent types of coated cutters before and after AFM, as well as uncoated WC?Co one, demonstrating that the boron?doped microcrystalline and undoped fine?grained composite diamond coated cutter after the AFM(AFM?BDM?UFGCD) is a good choice for the finish milling of the 6063 Al alloy in the present case, because it shows favorable machining quality close to the uncoated one, but much prolonged tool lifetime. Besides, compared with the micro?sized diamond films, it is much more convenient and e cient to finish the BDM?UFGCD coated cutter covered by nano?sized diamond grains, and resharpen its cutting edge by the AFM, owing to the lower initial surface roughness and hardness. Moreover, the boron incorporation and micro?sized grains in the underly?ing layer can enhance the film?substrate adhesion, avoid the rapid film removal in the machining process, and thus maximize the tool life(1040 m, four times more than the uncoated one). In general, the AFM is firstly proposed and discussed for post?processing the diamond coated complicated cutting tools, which is proved to be feasible for improving the cutting performance
基金Supported by National Natural Science Foundation of China(Grant No.52175124)Zhejiang Provincial Natural Science Foundation(Grant No.LZ21E050003)Fundamental Research Funds for the Zhejiang Universities(Grant No.RF-C2020004).
文摘The polishing efficiency of the soft abrasive flow(SAF)method is low,which is not in line with the concept of carbon emission reduction in industrial production.To address the above issue,a two-phase fluid multi-physics modeling method for ultrasonic-assisted SAF processing is proposed.The acoustics-fluid coupling mechanic model based on the realizable k-ε model and Helmholtz equation is built to analyze the cavitation effect.The results show that the pro-posed modeling and solution method oriented to ultrasonic-assisted SAF processing have better revealed the flow field evolution mechanism.The turbulence kinetic energy at different ultrasonic frequencies and amplitudes is stud-ied.Simulation results show that the ultrasonic vibration can induce a cavitation effect in the constrained flow chan-nel and promote the turbulence intensity and uniformity of the abrasive flow.A set of comparative polishing experiments with or without ultrasonic vibration are conducted to explore the performance of the proposed method.It can be found that the ultrasonic-assisted SAF method can improve the machining efficiency and uniformity,to achieve the purpose of carbon emission reduction.The relevant result can offer a helpful reference for the SAF method.
基金supported by the National Natural Science Foundation of China(Nos.52175124 and 52305139)the Natural Science Foundation of Zhejiang Province(Nos.LZ21E050003,LY17E050004,and LQ23E050017)+1 种基金the Zhejiang Provincial Postdoctoral Merit-Based Funding Project(No.ZJ2022068)the Open Foundation of the State Key Laboratory of Fluid Power and Mechatronic Systems(No.GZKF-202125),China.
文摘This paper reviews recent developments of the soft abrasive flow finishing(SAF)method in constraint space.The multiphase fluid dynamics modeling,material removal mechanism,auxiliary strengthening finishing techniques,and observation of surface impact effects by abrasive particles and cavitation bubbles are presented in brief.Development prospects and challenges are given for four aspects:thin-walled curved surfaces,biomedical functions,electronic information,and precise optical components.
基金supported by the National Natural Science Foundation of China(Grant Nos.50875242,50905163)Key Project of Natural Science Foundation of Zhejiang Province(Grant Nos.Z107517,Y1090836)
文摘Aiming at the problem of difficult contact finishing for mini structural surface in course of mould manufacturing,a new no-tool precision machining method based on soft abrasive flow machining(SAFM)was proposed.It allocated restrained component near surface machined,constituted restrained abrasive flow passage,and made the surface become a segment of passage wall.It could control turbulence abrasive flow in restrained passage,realize micro cutting for passage wall,and utilize the irregular motion of abrasive flow to eliminate the mono-directional marks on machined surfaces,and the precision could reach the specular level.A two-phase dynamic model of abrasive flow oriented to SAFM combined with discrete phase model(DPM)was established,the law of two-phase flow motion and the related physical parameters was obtained by corresponding numerical simulation method,and the mechanism of precision machining in SAFM was discussed.Simulation results show that the abrasive flow machining process mainly appears as translation of ablating location with the influence by granular pressure,and as the variation of machining efficiency with the influence by near-wall particle velocity.Thus via control of the inlet velocity and its corresponding machining time,it is supposed to work out the machining process according to the machining requirements by using the Preston equation to seek the relationship among velocity,pressure and material removing rate.By tracking near-wall particles,it can be confirmed that the movement of near-wall abrasive particles is similar to stream-wise vortices.The cutting traces on workpiece surfaces assume disorderly arrangement,so the feasibility of the SAFM method can be reaffirmed.
文摘Improvement of surface finish and material removal has been quite a challenge in a finishing operation such as abrasive flow machining （AFM）. Factors that affect the surface finish and material removal are media viscosity, extrusion pressure, piston velocity, and particle size in abrasive flow machining process. Performing experiments for all the parameters and accurately obtaining an optimized parameter in a short time are difficult to accomplish because the operation requires a precise finish. Computational fluid dynamics （CFD） simulation was employed to accurately determine optimum parameters. In the current work, a 2D model was designed, and the flow analysis, force calculation, and material removal prediction were performed and compared with the available experi- mental data. Another 3D model for a swaging die finishing using AFM was simulated at different viscosities of the media to study the effects on the controlling parameters. A CFD simulation was performed by using commercially available ANSYS FLUENT. Two phases were considered for the flow analysis, and multiphase mixture model was taken into account. The fluid was considered to be a Newtonian fluid and the flow laminar with no wall slip.
文摘Inconel 718 superalloy has extensive applications in a variety of industries such as the moulding,aerospace and medical due to its excellent mechanical features such as poor thermal conductivity,high strength at high temperatures and corrosion resistance.However,it is very difficult to process by traditional machining and finishing methods.Abrasive based finishing process is one of non-traditional finishing method applied to complex surfaces.Shot peening process is one of the surface treatment processes mostly applied to improve the surface strength.The superior advantages of these two processes are combined into one process.This newly developed and patented process is called as GOV process.In this study,the effects of GOV process parameters(number of cycles,steel ball size,media concentration)on the surface quality of Inconel 718 already pre-processed by wire electric discharge machining are investigated.The performance parameters are identified as surface roughness,material removal and white layer thickness.Surface finishing with the GOV process improves the surface roughness,Ra value by decreasing from 2.63μm to 0.46μm by removing micro-level chips up to 10.7 mg which is supported by SEM images.White layer formed due to nature of EDM process is completely removed from specimen surface.
