Study On The Mechanism Of Abrasive Flow Finishing Machining Based On The Hydrodynamic Effects

An abrasive surface finishing processing method is proposed for complex objects of high strength and toughness. The process is based on hydrodynamic interaction utilizing a multi-axis CNC machine, replacing the milling cutters with a cylindrical tool and immersing the complex object in a certain proportion abrasive liquid(the high speed spinning of the cylindrical tool determines the hydrodynamic interaction of the abrasive liquid – in order to remove some of the surface material). The method, similar to traditional abrasive finishing processing methods, has the precondition of not damaging dimensional precision and form accuracy to ensure surface integrity. Additional, it has the advantage of low motion precision, and overcome the challenges of controlling removed materials. In this paper theoretical and experimental research about the mechanism of processing method were carried out. The research can be summarized as follows:(1)The research is based on the basic principles of solid-liquid two-phase flow, using FLUENT discrete particle model to create a simulation analysis of the velocity and pressure fields; tracking the motion of individual particles in the flow field.(2)Through the theory of abrasive particle wear mechanism, combined with movement of abrasive particles in the flow field to build a single particle material removal model. The machining mode is from two-body abrasive to three-body polishing in the processing area where removed materials are determined by impact and shear.(3)A titanium alloy is used as material in this study. Experiments utilizing high speed CNC machines are performed. WGL surface profiling analyzer is utilized to measure results. A surface roughness of 3.0?m before processing to a roughness of 1.0?mafter processing proves the feasibility of abrasive flow processing method(utilizing a rotating tool, applied to a titanium alloy surface). And by observing the microscopic image of the surface after grinding and polishing to verify the material remove mechanism of two-body abrasive and three-body polishing.