TY - JOUR
T1 - Generic three-dimensional model of freeform surface polishing with non-Newtonian fluids
AU - Zhu, Wu Le
AU - Beaucamp, Anthony
N1 - Funding Information:
The authors would like to acknowledge Zeeko Inc. from UK for loading the polishing and measuring equipment. We also thank Prof. Watanabe Hiroshi from laboratory of molecular rheology, division of multidisciplinary chemistry, Kyoto University, for his helpful advice in understanding the rheology and polymer stabilization in this study, as well as Kyoto University student Yuuki Nishizaki for his help with carrying out some of the experimental work. This work was financially supported by the Grant-in-Aid for Scientific Research No. 20K14625 from the Japan Society for the Promotion of Science, and a donation fund from DMG Mori Seiki Co.
Funding Information:
The authors would like to acknowledge Zeeko Inc. from UK for loading the polishing and measuring equipment. We also thank Prof. Watanabe Hiroshi from laboratory of molecular rheology, division of multidisciplinary chemistry, Kyoto University, for his helpful advice in understanding the rheology and polymer stabilization in this study, as well as Kyoto University student Yuuki Nishizaki for his help with carrying out some of the experimental work. This work was financially supported by the Grant-in-Aid for Scientific Research No. 20K14625 from the Japan Society for the Promotion of Science , and a donation fund from DMG Mori Seiki Co.
Publisher Copyright:
© 2021 Elsevier Ltd
PY - 2022/1
Y1 - 2022/1
N2 - Non-Newtonian fluids are being increasingly considered for application in manufacturing. Their combination with compliant polishing techniques offers a promising approach for ultraprecision finishing of freeform surfaces. However, in-depth understanding of the underlying material removal mechanism and its link with slurry rheology has not been disclosed yet. In this study, a comprehensive three-dimensional dynamic modeling framework is presented, which enables accurate prediction of stress distribution, rheological flow, compliant deformation in 3D, as well as material removal behavior on curved workpieces. Supported by experimental tests and theoretical analysis, it is demonstrated that the viscosity peak gets shifted to a higher frequency by mixing starch and polymer, which makes high speed polishing with improved material removal rate possible. Meanwhile, it is found that the polymer additive prevents large size starch agglomeration and has high affinity with fine abrasives, both of which greatly contribute to the obtained scratch-free and nanoscale surface finish. Finally, the controllability and predictability of the process are demonstrated by polishing a bi-sinusoidal freeform surface onto a planar workpiece coated with nickel.
AB - Non-Newtonian fluids are being increasingly considered for application in manufacturing. Their combination with compliant polishing techniques offers a promising approach for ultraprecision finishing of freeform surfaces. However, in-depth understanding of the underlying material removal mechanism and its link with slurry rheology has not been disclosed yet. In this study, a comprehensive three-dimensional dynamic modeling framework is presented, which enables accurate prediction of stress distribution, rheological flow, compliant deformation in 3D, as well as material removal behavior on curved workpieces. Supported by experimental tests and theoretical analysis, it is demonstrated that the viscosity peak gets shifted to a higher frequency by mixing starch and polymer, which makes high speed polishing with improved material removal rate possible. Meanwhile, it is found that the polymer additive prevents large size starch agglomeration and has high affinity with fine abrasives, both of which greatly contribute to the obtained scratch-free and nanoscale surface finish. Finally, the controllability and predictability of the process are demonstrated by polishing a bi-sinusoidal freeform surface onto a planar workpiece coated with nickel.
KW - Compliant finishing
KW - Fluid dynamics
KW - Non-Newtonian fluid
KW - Removal mechanism
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U2 - 10.1016/j.ijmachtools.2021.103837
DO - 10.1016/j.ijmachtools.2021.103837
M3 - Article
AN - SCOPUS:85120404723
SN - 0890-6955
VL - 172
JO - International Journal of Machine Tool Design & Research
JF - International Journal of Machine Tool Design & Research
M1 - 103837
ER -