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Research Article | Open Access

Wear behavior of copper material removal during fluid jet polishing: A comparative study between experiment and simulation

Wenjing ZHANG1, Xin ZHANG1( ), Tiancheng AI1, Dan GUO1( ), Guoshun PAN1,2( )
State Key Laboratory of Tribology in Advanced Equipment, Tsinghua University, Beijing 100084, China
Guangdong Provincial Key Laboratory of Optomechatronics, Shenzhen 518057, China
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Graphical Abstract

Abstract

As a crucial part in micro-electromechanical manufacture, local ultra-precision processing of highly ductile copper is expected to be realized by fluid jet polishing (FJP), which widely utilized in optical elements. Since copper exhibits different wear behavior from stiff and brittle material, there is currently no abrasive wear prediction model applicable for copper to investigate the polishing mechanism. This research reveals that the copper material removal is dominated by deformation wear rather than cutting wear through abrasive jet impact experiments and localized wear scars analysis. A three-dimensional gas-liquid-particle triphasic wear model for copper in FJP is developed by considering impact energy and wear mechanism simultaneously. Ultimately, validation assessments at various working pressures and impingement angles achieve the goodness-of-fit up to 0.92–0.97 in quantitative comparison between simulations and experimental measurements, which demonstrate the wear prediction ability of the proposed model. This investigation facilitates a better understanding of copper wear mechanism and provides theoretical guidance for FJP process optimization.

Keywords

fluid jet polishing (FJP)wear mechanismcomputational fluid mechanicswear modelmaterial removal

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Friction
Volume 12 Issue 8,
August 2024
Pages 1680-1695
DOI: 10.1007/s40544-023-0771-5
Cite this article:
ZHANG W, ZHANG X, AI T, et al. Wear behavior of copper material removal during fluid jet polishing: A comparative study between experiment and simulation. Friction, 2024, 12(8): 1680-1695. https://doi.org/10.1007/s40544-023-0771-5

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Received: 15 March 2023
Revised: 05 April 2023
Accepted: 21 April 2023
Published: 12 January 2024
© The author(s) 2023.

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