Based on the non-Newtonian power-law fluid with shear thickening mechanism, shear thickening polishing (STP) as a novel ultra-precision machining method is proposed. The minimum thickness between non-Newtonian fluid of shear thickening polishing and workpiece is deduced through the study on the theory of shear elastic layer. According to Preston equation, the material removal mathematics model is deduced and founded. At constant velocity of flow (U), non-Newton shear thickening power-law fluid compared to the Newton fluid or shear thinning fluid can achieve higher material removal rate (MRR). MRR will further increase with the increasing of viscosity index n. When n is equal to 2 and consistency index K is equal to 0.32, MRR is exponential growth trend with the increase of U, which shows that increasing velocity improves the machining efficiency. Then a machining experiment of GCr15 bearing steel curved surface material is carried out on a shear thickening polishing machining system, the surface roughness of workpiece is decreased from Ra 105.95 nm to Ra 5.99 nm after 90 min processing, and mirror effect can be achieved. MRR of GCr15 (bearing steel) is up to 2.1 μm/h. The average error between the material removal theoretical value and processing experiment result is only 6.12%. The validation of established material removal mathematics model is verified.
LI Min, LÜ Binghai, YUAN Julong, DONG Chenchen, DAI Weitao
. Material Removal Mathematics Model of Shear Thickening Polishing[J]. Journal of Mechanical Engineering, 2016
, 52(7)
: 142
-151
.
DOI: 10.3901/JME.2016.07.142
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