Abstract
This study used fluid abrasive as a two-phase flow to investigate the composition and function of the cutting force of abrasive flow machining (AFM). The slip** cutting factor Kf describing the finishing ability of the viscoelastic fluid abrasive and the cutting factor KT of the abrasive phase are defined for the cutting force of AFM. The theoretical equation for calculating the cutting factors is given, and the test method of the variable sliding friction coefficient for cutting factors is proposed and tested in this study. The results show that the finishing force of AFM is proportional to the pressure of the flow field on the surface of a workpiece. The abrasive phase cutting factors are related to the abrasive particle size, mass mixing ratio, and surface characteristics of the workpiece, and not to the viscosity of the carrier. Further, the finishing force of the fluid abrasive can be enhanced by increasing the softener content.
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All data generated or analyzed during this study are included in this published article. The datasets used for this study are publicly available and anonymous.
Abbreviations
- ds :
-
Microbody
- P w :
-
Normal pressure of microbody (N)
- σ w :
-
Shear stress of microbody (N)
- dF T :
-
Finishing cutting force of microbody (N)
- dF ’ T :
-
Reaction force of dFT (N)
- Re:
-
Reynolds number
- ΔU :
-
Flow rate difference (mm/s)
- ∇P :
-
Pressure gradient (MPa)
- ψ m :
-
Mass mixing ratio
- d p :
-
Particle size of abrasive particles (μm)
- ø :
-
Shape coefficient
- H w :
-
Surface hardness (N/mm2)
- Ra w :
-
Surface roughness (μm)
- G 0 :
-
Weight of workpiece (N)
- G top :
-
Weight of upper force sensor (N)
- N D0 :
-
Reading difference (N)
- F M1 :
-
Total force (N)
- F T1 :
-
Total cutting force (N)
- K f :
-
Sliding cutting factor of fluid abrasives
- F sl :
-
Sliding force of abrasive particles (N)
- F pl :
-
Plowing force of abrasive particles (N)
- F ch :
-
Cutting force of abrasive particles (N)
- μw :
-
Coefficient of friction
- F f,sl :
-
Sliding force of abrasive particles per unit area (N)
- F N :
-
Normal force of abrasive particles (N)
- F t,pl :
-
Plowing force of abrasive particles per unit area (N)
- F f,pl :
-
Friction force of abrasive particles per unit area (N)
- k pl :
-
Plow coefficient
- K re :
-
Tangential cutting coefficient
- h :
-
Thickness of the undeformed chips (μm)
- dz :
-
Cutting depth (μm)
- k t :
-
Cutting coefficient of the single abrasive particle
- F t,ch :
-
Cutting force of abrasive particles (N)
- K dRa :
-
Coefficient
- l :
-
Cutting distance of abrasive particles (mm)
- W v :
-
Cutting volume of abrasive particles (mm3)
- A s :
-
Projection area of the abrasive particle cutting part (mm2)
- N f :
-
Number of abrasive particles involved in sliding
- N pl :
-
Number of abrasive particles involved in plowing
- N t :
-
Number of abrasive particles involved in microcutting
- N s :
-
Total number of abrasive particles
- ds p :
-
Contact area between abrasive particles and workpiece (mm2)
- ds c :
-
Contact area between the carrier and the workpiece (mm2)
- K T :
-
Cutting factor of abrasive particle phase
- μc :
-
Coefficient of sliding friction
- μ c1 :
-
Friction coefficients of carrier VLFA-I and workpiece
- μ c2 :
-
Friction coefficients of carrier VLFA-II and workpiece
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Funding
This work is supported by the Natural Science Basic Plan in Shanxi Province of China (201701D121074).
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Zhiguo Dong contributed to the derivation of theory and design of experiments and was a major contributor in writing the manuscript. Yuchao Zhang contributed to the analysis of data and operation of experiments. Hongbo Lei contributed to the operation of equipment and collection of data. All authors read and approved the final manuscript.
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Dong, Z., Zhang, Y. & Lei, H. Cutting factors and testing of highly viscoelastic fluid abrasive flow machining. Int J Adv Manuf Technol 112, 3459–3470 (2021). https://doi.org/10.1007/s00170-021-06619-0
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DOI: https://doi.org/10.1007/s00170-021-06619-0