A Review on Magnetorheological Jet Polishing Technique for Microstructured Functional Surfaces
Abstract
:1. Introduction
2. Machining Mechanism of MJP Polishing Technique
2.1. Principle of MJP
2.2. Materials Removal Mechanism
- (1)
- In the wall jet area, the tensile strength of the material is much smaller than the compressive strength of the material. Therefore, when the fluid flows on the wall, the impact angle of the particles along the wall to the workpiece surface decreases from the center, and the radial velocity rapidly increases to the maximum and then decreases gradually along the streamline. Low impact angle and high radial velocity can produce maximum micro-cutting efficiency, resulting in a W-shaped material removal profile [52,53]. From the microscopic removal process, when the fluid flows over the workpiece surface, as shown in Figure 4a,b, the peak of the rough surface is first contacted by the abrasive, as shown in Figure 4c. Abrasive contact with the bottom of the rough surface is a very low probability; therefore, the peak is removed first and then layer by layer cutting, which is the main reason for the roughness reduction after polishing.
- (2)
- In the central area, a small amount of material is removed when the workpiece surface is impacted by the jet fluid. The impact process can be described as the effect of the fluid on the normal pressure of the surface, the distribution of which is a predictable function of position and does not vary with time. Under impact, the surface of the workpiece forms fragments and peels off, and the removal of material is random. In the macroscopic expression, a small amount of material can be removed, which is why the removal rate of the impact zone is not zero in the actual polishing results. This random removal process of the workpiece surface has a low removal efficiency but has a great impact on the roughness [53].
2.3. Rheological Characteristics Analysis of MR Fluid
2.4. Material Removal Model
3. MJP Processing System
3.1. Design and Analysis of Magnetic Field
3.2. Optimization of the Nozzle Structure
3.3. Circulating Stirring System
3.4. On–Line Monitoring of MR Fluid
3.5. The Special MJP System
4. Study on MJP Processing Technique
4.1. The Jet Direction
4.2. Effect of Incident Angle on Material Removal Rate
- (1)
- The velocity distribution cloud diagram and pressure distribution cloud diagram of vertical incidence are shown in Figure 16. ① After reaching the surface of the workpiece, the velocity in the center area of the fluid decreases to 0. In the process of diffusion, as a form of shear flow with a large concentration, the liquid does not spatter in the X direction but always flows on the surface of the workpiece. This is different from the flow state in abrasive jet polishing. ② During diffusion, the velocity rapidly increases to the maximum and then decreases due to the presence of shear force. However, the effective polishing area is only less than 20 mm, and in such a small area, the velocity approximately maintains the maximum value. The pressure action area is small and the distribution form is more symmetrical. In summary, the pressure on the workpiece surface presents a circular distribution. The center of the circle is the central area of the magnetic jet collision, and the diameter is about the distance of three to four nozzles. The pressure distribution form of the fluid on the workpiece is similar to the Gaussian shape distribution, and the pressure in the middle area is high and decreases in the radial direction [51].
- (2)
- The velocity distribution cloud diagram and pressure distribution cloud diagram for oblique incidence are shown in Figure 17. ① In terms of distribution form, the force on the workpiece surface is asymmetric; in terms of fluid flow, the incident angle is the obtuse angle, and the flow is larger. ② Of the removal effect on the workpiece surface, when the flow is larger, the speed is large, and the pressure is large, which leads to the result of a high removal rate. Due to the obtuse incidence removal function, the obtuse angle removal is going to be a little bit more efficient [51].
- (3)
- The positive pressure curve is analyzed, as shown in Figure 18. ① The pressure and shear force in the acute angle area changes faster. ② Compared with the distribution at normal incidence, the whole function shows a slanted Gaussian-like shape. The maximum pressure distribution is still in the corresponding position of the jet center. ③ The shear force form is very different from the vertical incidence, as shown in Figure 19. The asymmetric form is manifested to a large extent, and the shear force has a significant influence on the removal of the workpiece.
4.3. Relationship between Jet Velocity and Removal Rate
4.4. Path Programming
4.5. Effect of Processing Technique
5. Conclusions
- (1)
- The stability and efficiency of the removal function need to be studied urgently. For large diameter or more complex surfaces, the processing cycle is often very long, needs longer continuous working time, better stability of magnetic jet fluid, and polishing equipment to meet the requirements of high certainty and high-efficiency polishing. To derive a more accurate material removal function, it is necessary to deeply study the properties of polishing fluid with rheological effect, to solve the problem of fluctuation of polishing fluid composition concentration and rheological properties during the polishing process, and to realize the stability and controllability of polishing fluid rheological properties such as viscosity and hardness by controlling the auxiliary field. Based on theoretical and simulation tests, we will further study the removal mechanism of workpiece materials and optimize the polishing fluid configuration and polishing parameters according to the physicochemical characteristics of different materials.
- (2)
- New techniques and new principles of magnetorheological jet polishing still need to be developed. At present, it is urgent to develop a composite machining method, such as one combined with ultrasonic vibration machining to solve the problem of the low removal rate and low machining efficiency of magnetic jet polishing.
- (3)
- Deterministic removal model for magnetorheological jet polishing needs to be established. The current research is based on the Preston equation, which divides the pressure on the workpiece into several parts, calculates them separately, and then superposes them. When the material removal model is established, it is simply considered from the two-dimensional direction, without the in-depth consideration of the model from the three-dimensional direction. It is necessary to adopt a reasonable magnetic jet hydrodynamic model to establish a universal and unified deterministic removal model system to adapt to the processing of various profiles.
- (4)
- The process needs to be modified and accurately controlled. Based on completely determining the removal function and the correction function, the algorithm relationship between the removal function and the correction function must be taken into account to control the various movements of the nozzle to achieve the removal of the determined quantity, and a reasonable algorithm of the material removal rate and dwell time should be adopted. To achieve high precision and surface integrity machining of product parts, in addition to accurate material removal functions/models, there is an urgent need to propose more accurate polishing removal dwell time algorithms and path planning functions to achieve the controllable removal of points, lines, and surfaces in order to improve the accuracy of workpiece detection during polishing, to effectively reflect the changes in workpiece surface morphology and material removal during the polishing process, and to accurately characterize the material removal distribution in the processing area.
- (5)
- The online inspection technique machining process needs to be improved. MJP machining workpiece surface measurement is currently mainly on the workpiece after processing offline detection, which will affect the efficiency of processing, automatic compensation accuracy, and workpiece surface quality to a certain extent. Therefore, the development of the MJP online detection and automatic compensation processing technique is also one of the key issues [100].
Author Contributions
Funding
Data Availability Statement
Conflicts of Interest
References
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Parameter | Unit | Data |
---|---|---|
Nozzle outlet diameter | mm | 2 |
The workpiece length | mm | 50 |
Processing distance | mm | 50 |
Initial fluid velocity | m·s−1 | 40 |
The initial pressure | Pa | 101,325 |
Authors | Work Material | Studies | Data |
---|---|---|---|
Zhang et al. [50,63] | K9 glass | PV, RMS | PV: 0.563 to 0.176 μm RMS:0.137 to 0.034 μm |
Dai et al. [58] | K9 glass | PV | 0.563 to 0.176 μm |
Wang et al. [95] | K9 glass | PV, RMS | PV: 0.162 to 0.024 μm RMS:0.043 to 0.003 μm |
Yang et al. [69] | K9 glass | Ra | 4.86 nm |
Li et al. [96] | BK7 glass | RMS | 40 to 6.8 nm |
Kim et al. [68] | BK7 glass | RMS | 1.3 nm |
Kordonski et al. [41] | PCA | PV, RMS | PV: 1740 to 133 nm RMS:255 to 12.1 μm |
Lu et al. [98] | Steel | Ra | 812 to 88 nm |
Lee et al. [64,99] | Cu, Ni | Ra | Cu:1.84 nm Ni:2.31 nm |
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Song, D.; Du, H.; Lin, J.; Zhou, X.; Wang, R. A Review on Magnetorheological Jet Polishing Technique for Microstructured Functional Surfaces. Lubricants 2022, 10, 237. https://doi.org/10.3390/lubricants10100237
Song D, Du H, Lin J, Zhou X, Wang R. A Review on Magnetorheological Jet Polishing Technique for Microstructured Functional Surfaces. Lubricants. 2022; 10(10):237. https://doi.org/10.3390/lubricants10100237
Chicago/Turabian StyleSong, Dunlan, Hongguang Du, Jieqiong Lin, Xiaoqin Zhou, and Rongqi Wang. 2022. "A Review on Magnetorheological Jet Polishing Technique for Microstructured Functional Surfaces" Lubricants 10, no. 10: 237. https://doi.org/10.3390/lubricants10100237