Numerical modelling and processing experiment of gas-liquid-solid three phase rotary abrasive flow machining

Abstract

Abstract Enhancing the processing efficiency and surface quality of difficult-to-machine materials such as large-area titaniferous alloy parts is the focus of low-carbon manufacturing. Here, we present a novel microbubble enhancement effect-based three-phase rotary abrasive flow polishing method (RGLSP). The characteristics of the high-speed rotary flow are calculated by the mixture model and modified realizable k-ε turbulence model. The simulation results reveal the dynamic characteristics of the high-speed turbulent vortex flow field formed by the three-phase abrasive flows in the constrained flow passages. The results show that the pitch-down angle of the processing medium inlet is the important parameter that affects the impact distribution features, and there is an optimal value for the impact characteristics of the rotary flow. Then the processing tool and RGLSP experimental platform are established, and the RGLSP method can improve the machining efficiency by 60%. The RGLSP method also can improve the surface quality of material without subsurface damage and the roughness can reach Ra 0.1µm after 150min machining.