Study On The Effect Of Process Parameters On Surface Quality In Abrasive Flow Machining

In aerospace,biomedicine,automobile manufacturing and other fields,abrasive flow machining technology is widely used because of its good machining accessibility and excellent polishing effect.However,due to many factors affecting the surface quality of abrasive flow machining,the cutting process is also very complicated.For a long time,there is only a small amount of empirical data to determine the process parameters of abrasive flow machining,and there is no systematic data reference for various machining requirements,So far,no systematic quantitative analysis of abrasive flow machining process was established.In order to improve the surface quality of abrasive flow machining,it is necessary to conduct quantitative research on the influence of abrasive flow machining process parameters on the machining effect,with the purpose of mastering the influence laws of various process parameters on the surface quality after machining,so that the surface quality and precision of the workpiece after machining can be controlled,to meet with the deeper requirements for polishing technology at this stage,and to make the abrasive flow machining technology applied in a wider range.In this paper,the abrasive flow machining process parameters are taken as the research object.Through experimental research and theoretical analysis,the effects of various process parameters on surface quality are systematically studied.The main contents include:According to the abrasive flow machining technology,the principle of abrasive flow machining is expounded,and the removal mechanism of abrasive flow machining materials is revealed.The design of the fixture used in abrasive flow machining is analyzed in detail,the characteristics of the fixture are introduced,and the principles to be followed in the process of fixture design are expounded.The selection of the components of abrasive media is discussed,and the influence of different components on the properties of abrasive media is analyzed.Aiming at the problem that there are many factors affecting the surface quality of abrasive flow machining,the mirror and milled surface samples are selected as the initial samples of the experiment,the special fixture is designed,and the experimental research on the influence of three kinds of process parameters on the surface quality based on machine tool control,abrasive media and workpiece is carried out.The extrusion pressure,cycle times,viscosity,mass fraction of abrasive media,and The influence of process parameters such as abrasive particle size and workpiece initial texture on the surface quality after abrasive flow machining.The experimental results show that the surface quality of the sample can be better when the extrusion force is small,the viscosity and mass fraction of abrasive are large,and the abrasive particle size is "large first and then small".In addition,when the angle between the initial grain direction and the abrasive flow direction is 90 °,the machining effect is the best.On this basis,the feasibility of abrasive flow polishing of gear parts is studied.For a certain type of spur gear,the gear abrasive flow polishing experiment was carried out.Through the design of the "tooth like" gear fixture,the uniform polishing of the gear tooth surface was realized,the hard polishing areas such as the tooth root were effectively polished,the tooth profile at the tooth end was not rounded,and the tooth profile accuracy was effectively maintained.After abrasive machining,the roughness Sa along the axial direction of the tooth surface was reduced from the initial 0.123 μm reduced to 0.042 μm.Sz from 1.535 μm reduced to 0.261 μm the roughness Sa along the radial direction of the tooth surface changes from the initial 0.649 μm reduced to 0.511 μm.Sz from 2.331 μm reduced to 1.044 μm.At the same time,the gear abrasive flow experiment verifies the conclusion of the process parameters in this paper.