Fluid jet polishing: removal process analysis

Fluid jet polishing is an emerging process which possesses the advantages of localized force and less heat generation, as well as the stable and controllable material removal function without tool wear. Due to the complex machining mechanism, it is still difficult to model the material removal rate and predict the surface generation for fluid jet polishing. In this article, theoretical and experimental investigation of three-dimensional-structured surface generation by fluid jet polishing has been carried out. A surface topography simulation model is established for predicting the three-dimensionalstructured surface generation by fluid jet polishing. A series of polishing experiments have been conducted to optimize the process parameters of fluid jet polishing and the fabrication of three-dimensional-structured surfaces. In terms of the pattern of three-dimensional-structured surfaces generated, the simulation results are found to agree with the experimental results.

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“…This is due to the cutting, collision and shearing actions between the abrasive particles and the surface of metal workpieces. 4…”

Section: Polishing Mechanism Of Fjpmentioning

confidence: 99%

“…Premixed slurry is ejected out from a nozzle to the workpiece at appropriate speed. 4 As direct contacts do not exist in the process and the slurry remains circulating, FJP has low tool wear rate. The circulating slurry also assists in minimizing the problem of thermal effect and removing the debris from the workpiece.…”

Section: Introductionmentioning

confidence: 99%

Theoretical and experimental investigation of three-dimensional-structured surface generation using fluid jet polishing

Cheung

Ren

2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Accordingly, in 1998, Fahnle, et al [12] adopted a low-pressure micro-abrasive jet with a nozzle in a controllable way to impose the impacts on the workpieces. The material removal process of AJP was further analysed in 1999 by Fahnle, et al [13], resulting significant improvement in the surface quality of the complex aspherical optical component. It was found that the geometry precision of the polishing area depends on the nozzle diameter, but nozzles of tiny size are easily clogged or worn out.…”

Section: Introductionmentioning

confidence: 99%

Constrained Abrasive Jet Polishing with a Tangentially Aligned Nozzle Shroud

Yuan

Chen

Wen

2021

Preprint

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In order to improve surface polishing quality and efficiency for hard and brittle components, a novel nozzle with specifically designed shroud was proposed for an abrasive jet polishing process. The removal mechanism of the abrasive jet under such a nozzle was investigated by simulating the jet flow in the interaction area of the nozzle shroud and workpiece. The simulation results show that the speed of the abrasive jet increases greatly by the shroud and the direction of the jet is aligned near parallel to the workpiece surface to minimize impact damage to workpiece surface. The constrained abrasive jet polishing (CAJP) experiments were conducted on the quartz glass component, a typical hard and brittle material, showing that the material removal mainly relied on the shearing and scratching of the workpiece surface rather than the mechanical shock impacts, which is consistent with the simulation findings.

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“…Besides, diamond turning marks are unavoidable, and surface fracture can be easily induced when processing brittle material such as glass or ceramics. Hence, various computer-controlled optical surfacing (CCOS) methods have been developed over the past decades including magnetorheological finishing [4], elastic emission machining [5], fluid jet polishing [6], bonnet polishing [7], etc.…”

Section: Introductionmentioning

confidence: 99%

Zernike mapping of optimum dwell time in deterministic fabrication of freeform optics

Zhu

Beaucamp

2019

Opt. Express

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In optics fabrication technologies such as computer controlled optical surfacing (CCOS), accurate computation of the dwell time map plays an essential role in the deterministic performance of the fabrication process. However, it is still difficult for existing methods to derive smooth dwell time maps that reduce dynamic stressing on the machine especially at the aperture edge region, while retaining fine correction capability on freeform optics. To answer these challenges, we propose a new method based on Zernike decomposition and improved differential evolution optimization of the dwell time map, which can be applied to time-dependent optics fabrication processes such as fluid jet machining. Simulations and experiments based on a bisinusoidal freeform design were carried out to assess the feasibility of the proposed methodology. With appropriate fluid jet pressure, a bi-sinusoidal optical surface with demanding form error target of sub-100 nm in peak-to-valley was achieved, showing a remarkable improvement on the state-of-the-art, while keeping a good average surface roughness of 2.6 nm Ra on the optical glass.

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Fluid jet polishing: removal process analysis

Cited by 22 publications

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Theoretical and experimental investigation of three-dimensional-structured surface generation using fluid jet polishing

Theoretical and experimental investigation of three-dimensional-structured surface generation using fluid jet polishing

Constrained Abrasive Jet Polishing with a Tangentially Aligned Nozzle Shroud

Zernike mapping of optimum dwell time in deterministic fabrication of freeform optics

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