Research On The Polishing Process And Apparatus Based On The Electromagnetic-field Remote Manipulation

With the approach of the 5G era,the development of mechanized and artificial intelligence in automation,ultra-precision machining is enhancing the pivotal role in the fields of industrial manufacturing,logistics,transportation,medical welfare and national defense industries.The most important step in the mechanism,which influences the life and performance of core components is ultra-precision polishing.At present,ultra-precision polishing mainly includes Bonnet Polishing,Ion Beam Processing,MRF and Elastic Emission Machining,etc.Although each method can achieve precise surface,it has a common limitation.It cannot polish complex surfaces and workpieces with complex internal cavity structures.Therefore,this paper proposes a new polishing method.Based on the traditional polishing,MRF and MAF principles,a new theory about external magnetic field controlling polishing tools in polishing is proposed.And polishing mechanism of generation of a magnetic field is established.And verified the principle of polishing feasibility,so the paper concludes the result about the surface in cavity roughness of aluminum alloy.The optimal factors affecting polishing are verified by orthogonal experiment.In this paper,we use the magnetic effect of current,Biot-Savart's law and Maxwell's equations to establish a mechanism that can generate specific rotating and gradient magnetic fields according to the different current of incoming conductor(Helmholtz coil and Maxwell coil).Therefore,using the torque generated by the rotating magnetic field and the force generated by the gradient magnetic field to drive the unfixed polishing tools at any position in the space.The movement in space of 6 degrees of freedom of the polishing tools is successfully manufactured,and finally the polishing pressure and the polishing speed are generated.Finally completed the polishing inside the cavity of Aluminum alloy.(1)Design the arrangement of the rotating magnetic field by the Biot-Savar's law.Calculate the magnitude and orientation of the magnetic field generated by the wire.A uniform rotating magnetic field is generated by a pair of coaxial coils with the same current.A gradient magnetic field is generated by a pair of coaxial coils with a reverse current.Finally,this paper matched the relationship between the magnitude and orientation of the rotation magnetic field with the input current.And this paper matched the gradient magnetic field with the input current.(2)Design the parameters of structural and material of the entire polishing device.According to the characteristics of the coil material,the structural characteristics of the coil,the requirements of size of the polishing table,the requirements of magnetic field and the gradient magnitude of the magnetic field,electromagnetic constraints,and electromechanical controlling equipment limits,this paper finally gives the size parameters of the five pairs of coils,and the reference range of the size and performance ability of the polishing apparatus.(3)Using COMSOL and ANSYS software to analyze the field of the entire electromagnetic physics field and force of polishing tools to verify the theoretical results.The force in simulation of the polishing tools is the same as the theoretical verification.Finally,simulate the force and rotation of the polishing tools under the different condition of the superimposed magnetic field.(4)The formation of the polishing theory was verified by the construction of the test bench and the experiment of polishing of the aluminum.And this paper finds the excellent combination of three polishing factors through the orthogonal experiment.And the dominated factor in polishing factors is polishing time in rational range.This paper compares the previous and polished surface roughness of aluminum.