目的 解决大深径比增材制造非直小孔内表面抛光不均匀的难题,实现对增材制造非直小孔的均匀抛光。方法 建立Fluent二维瞬态仿真模型,通过双向容积交变空化数值仿真,分析了容积交变非直小孔内空化流场特性,探究不同频率及行程对新型流场分布的影响规律,并在双向容积交变空化实验装置上,对R4600树脂材料增材制造加工的非直小孔试件内表面进行抛光实验验证,采用Rtec UP-3000三维轮廓仪对不同试样进行内表面粗糙度测量。结果 在容积交变作用下,非直小孔内的空化流场含气率、湍流强度均呈周期性变化,且随着频率、行程的增加,流场内空化效应增强。随着频率、行程及时间的增加,非直小孔内表面粗糙度Ra值出现先降后增的趋势,其中,当时间t=3 h、频率f=20 Hz、行程H=20 mm时,小孔内表面粗糙度最大降低了50.09%,但也开始出现空蚀凹坑,导致Ra值增大。结论 双向容积交变空化对增材制造的非直小孔内表面抛光效果明显,且工艺参数直接影响着抛光质量。
Abstract
The work aims to solve the problem of non-uniform polishing of the inner surface of non-straight holes made by additive with large aspect ratio and realize uniform polishing of non-straight holes in additive manufacturing. A Fluent two-dimensional transient simulation model was established and the characteristics of the cavitation flow field in non-straight holes were analyzed through bidirectional volume alternating cavitation numerical simulation. The effect of different parameters on it was explored. The bidirectional volume alternating cavitation experimental device was used to verify the inner surface polishing experiment of non-straight holes in R4600 resin material, and a Rtec UP-3000 3D profilometer was used to measure the internal surface roughness of different samples. The void fraction and turbulence intensity in the flow field showed periodic changes. Moreover, as the frequency and stroke increased, the cavitation effect within the flow field got intensified. With the increase of frequency, stroke and time, the roughness Ra of the inner surface of the non-straight hole showed a trend of first decreasing and then increasing. When time t=3 h, frequency f=20 Hz, and stroke H=20 mm, the surface roughness inside the holes decreased by a maximum of 50.09%. However, cavitation pits also began to appear, causing the Ra value to increase. In conclusion, the bidirectional volume alternating cavitation method has a significant effect on polishing non-straight holes in additive manufacturing, and process parameters directly affect the polishing quality.
关键词
双向容积交变 /
空泡溃灭 /
增材制造 /
非直小孔 /
抛光
Key words
bidirectional volume alternation /
cavitation /
additive manufacturing /
non-straight holes /
polishing
{{custom_sec.title}}
{{custom_sec.title}}
{{custom_sec.content}}
参考文献
[1] TAO S, GAO Z S, SHI H Y.Characterization of Printed Circuit Board Micro-Holes Drilling Process by Accurate Analysis of Drilling Force Signal[J]. International Journal of Precision Engineering and Manufacturing, 2022, 23(2): 131-138.
[2] DEEPU P, JAGADESH T.A Review on Short and Ultrashort Pulsed Laser Microdrilling: Materials, Mechanism, Methods, and Applications[J]. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 2024, 46(7): 408.
[3] 孙海江, 邢飞, 卞宏友, 等. 增减材混合制造技术的研究现状与进展[J]. 制造技术与机床, 2022(12): 15-23.
SUN H J, XING F, BIAN H Y, et al.Research Status and Progress of Hybrid Additive Manufacturing Technology[J]. Manufacturing Technology & Machine Tool, 2022(12): 15-23.
[4] YADAV R, YADAV S S, DHIMAN R, et al.A Comprehensive Review on Failure Aspects of Additive Manufacturing Components under Different Loading Conditions[J]. Journal of Failure Analysis and Prevention, 2024, 24(5): 2341-2350.
[5] LEE J, HUSSAIN A, HA J, et al.Mechanical Properties of Ti-6Al-4V Thin Walls Fabricated by Laser Powder Bed Fusion[J]. Additive Manufacturing, 2024, 94: 104484.
[6] WANG S H, NING J S, ZHU L D, et al.Role of Porosity Defects in Metal 3D Printing: Formation Mechanisms, Impacts on Properties and Mitigation Strategies[J]. Materials Today, 2022, 59: 133-160.
[7] ZHOU Y G, LI H Y, MA L J, et al.Study on Hole Quality and Surface Quality of Micro-Drilling Nickel-Based Single-Crystal Superalloy[J]. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 2020, 42(6): 341.
[8] PINTAUDE G, GRABARSKI M I, MOREIRA P P.Maintenance of Hydroerosive Grinding Efficiency Based on Particle Size Distribution of Abrasive Fluid[J]. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 2019, 41(2): 94.
[9] MOHSENI-MOFIDI S, PASTEWKA L, TESCHNER M, et al.Magnetic-Assisted Soft Abrasive Flow Machining Studied with Smoothed Particle Hydrodynamics[J]. Applied Mathematical Modelling, 2022, 101: 38-54.
[10] BHARDWAJ A, SRINIVAS K, CHAUDHARY R.Morphology of Finished Brass Surface by Thermal Additive Centrifugal Abrasive Flow Machining Process Using Novel Electrode[J]. JOM, 2024, 76(1): 510-521.
[11] MOHAMMADIAN N, TURENNE S, BRAILOVSKI V.Surface Finish Control of Additively-Manufactured Inconel 625 Components Using Combined Chemical-Abrasive Flow Polishing[J]. Journal of Materials Processing Technology, 2018, 252: 728-738.
[12] GE J Q, LI C, GAO Z Y, et al.Softness Abrasive Flow Polishing Method Using Constrained Boundary Vibration[J]. Powder Technology, 2021, 382: 173-187.
[13] ZHAO J, HUANG J F, WANG R, et al.Investigation of the Optimal Parameters for the Surface Finish of K9 Optical Glass Using a Soft Abrasive Rotary Flow Polishing Process[J]. Journal of Manufacturing Processes, 2020, 49: 26-34.
[14] KUMAR S, JAIN V K, SIDPARA A.Nanofinishing of Freeform Surfaces (Knee Joint Implant) by Rotational-Magnetorheological Abrasive Flow Finishing (R-MRAFF) Process[J]. Precision Engineering, 2015, 42: 165-178.
[15] XU G W, FANG H M, SONG Y M, et al.Optimal Design and Analysis of Cavitating Law for Well-Cellar Cavitating Mechanism Based on MBD-DEM Bidirectional Coupling Model[J]. Agriculture, 2023, 13(1): 142.
[16] CHEN Y, YIN C, SONG Y T.Application of Hydrodynamic Cavitation in the Field of Water Treatment[J]. Chemical Papers, 2023, 77(7): 3521-3546.
[17] ZHANG L, DING C, HAN Y J, et al.Investigation into a Novel Pulsating Cavitation Air Jet Polishing Method for Ti-6Al-4V Alloy[J]. Tribology International, 2022, 175: 107837.
[18] CHEN F J, WANG H, YIN S H, et al.Cavitation Water-Suction Polishing of Metallic Materials under Negative-Pressure Effect[J]. Journal of Materials Processing Technology, 2019, 273: 116257.
[19] CHEN F J, WANG H, TANG Y, et al.Novel Cavitation Fluid Jet Polishing Process Based on Negative Pressure Effects[J]. Ultrasonics Sonochemistry, 2018, 42: 339-346.
[20] 陈铁牛, 郭钟宁, 曾柏文, 等. 激光诱导空泡微孔抛光机理及实验研究[J]. 中国机械工程, 2018, 29(3): 273-278.
CHEN T N, GUO Z N, ZENG B W, et al.Study on Micro-Hole Polishing Mechanism and Experiments Based on Laser-Induced Cavitation Bubbles[J]. China Mechanical Engineering, 2018, 29(3): 273-278.
[21] NAGALINGAM A P, THIRUCHELVAM V C, YEO S H.A Novel Hydrodynamic Cavitation Abrasive Technique for Internal Surface Finishing[J]. Journal of Manufacturing Processes, 2019, 46: 44-58.
[22] NAGALINGAM A P, SANTHANAM V, DACHEPALLY N K G, et al. Multiphase Hydrodynamic Flow Characterization for Surface Finishing the Laser Powder Bed Fused AlSi10Mg Conformal Cooling Channels[J]. Journal of Manufacturing Processes, 2021, 68: 277-292.
[23] NAGALINGAM A P, YEO S H.Controlled Hydrodynamic Cavitation Erosion with Abrasive Particles for Internal Surface Modification of Additive Manufactured Components[J]. Wear, 2018, 414: 89-100.
[24] LI F Z, ZHANG B, GUO Y Q, et al.Novel Bidirectional Volume Alternating Cavitation Technique for the Inner Surface Finishing of Small Holes[J]. International Journal of Precision Engineering and Manufacturing, 2025, 26(5): 1049-1060.
[25] 张博, 李富柱, 王匀, 等. 小孔流道内容积交变空化流场特性分析[J]. 精密成形工程, 2023, 15(10): 204-211.
ZHANG B, LI F Z, WANG Y, et al.Analysis of Cavitation Flow Field Characteristics of Small Hole Runner Based on Volume Alternating Cavitation[J]. Journal of Netshape Forming Engineering, 2023, 15(10): 204-211.
[26] YIN J L, CHEN W G, SONG Y C, et al.Research on Bubble Generation Method Based on Flow Control Mechanism[J]. International Journal of Advanced Nuclear Reactor Design and Technology, 2023, 25: 42-51.
基金
装备预先研究领域基金（8092301201）
PDF(3386 KB)
渝公网安备 50010702501719号 渝ICP备15012534号-4
