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摘要
A new method is proposed to realize abrasive flow uniformity precise finishing processing by inserting a similar mandrel, aiming at the inconsistent surface quality problem caused by the changes of non-circular cavity curvature radius in abrasive flow machining process. The infinitesimal body dynamic model for abrasive flow machining is established by using the power-law equations of non-Newtonian fluids to analyse the influencing factors of the uneven distribution of surface shear stress in abrasive flow machining process; and relevant demonstration is carried out by numerical calculation and simulation via COMSOL software as well. A mold core similar to ellipse cavity is utilized to improve the uneven distribution of shear stress on the surface of non-circular cavity. Experimental studies are carried out to test relevant data such as the wall pressure and surface roughness of the elliptical cavity. The experimental results show that, the simulated value error of the shear stress in both major and minor axis directions of the elliptical runner decreased from 9.87% to 0.39%, which indicated the shear stress distribution tended to be consistent; moreover, the processing pressure and surface roughness also tended to be consistent, the average pressure differences of the axial and radial directions of the elliptical flow channel were respectively only 0.03 and 0.11 MPa; the difference value of surface roughness decreased from 0.212 μm (before inserting the mandrel) to 0.005 μm; The uneven distribution of shear stress in abrasive flow processing process is solved and improved by the method of homogenizing flow channel, which will provide an important reference for the high-quality precision processing of non-circular cavities. ? 2022 Editorial Office of Chinese Journal of Mechanical Engineering.
