AI Chat Paper
Note: Please note that the following content is generated by AMiner AI. SciOpen does not take any responsibility related to this content.
{{lang === 'zh_CN' ? '文章概述' : 'Summary'}}
{{lang === 'en_US' ? '中' : 'Eng'}}
Chat more with AI
Home Friction Article
PDF (4 MB)
Collect
Submit Manuscript AI Chat Paper
Show Outline
Outline
Show full outline
Hide outline
Outline
Show full outline
Hide outline
Research Article | Open Access

Modeling and analysis for material removal and surface roughness in fluid jet polishing of optical glass

Zhongchen CAO1Ming WANG1Haitao LIU1( )Tian HUANG1,2
Key Laboratory of Mechanism Theory and Equipment Design of Ministry of Education, Tianjin University, Tianjin 300072, China
School of Engineering, The University of Warwick, Coventry CV4 7AL, UK
Show Author Information

Graphical Abstract

Abstract

Fluid jet polishing (FJP) is a non-contact polishing technology that can fabricate free-form optical surfaces with sub-micron-level form accuracy and nano-level surface roughness, especially for hard and brittle materials. The surface generation model of FJP can be used to guide the determination and optimization of process parameters and is of great significance for understanding the evolution mechanism of surface microtopography. However, predictive models for the microscopic topography of polished surfaces are still lacking. This study established a macroscopic surface profile model for predicting 3D material removal characteristics and surface texture by combining the 3D computer fluid dynamics (CFD) simulation model and single-particle erosion mechanism. A fractal theory-based erosion model has been built to calculate the material removal caused by the erosion of a single abrasive particle on the rough surface; thus, it predicts the micro-topography and surface roughness of the polished samples. A series of polishing experiments were conducted to analyze the feasibility and accuracy of the model quantitatively and study the influence mechanism of process parameters on the material removal characteristics and surface quality. Results indicated that the models could well predict material removal and surface roughness. The prediction accuracy of the surface roughness Ra and maximum removal depth is better than 91.6% and 90%, respectively. It is also found that the material removal rate of FJP could reach 0.517 mm3/min, and the surface roughness convergence rate could reach 62.9%.

References

[1]
Li Y G, Zheng N, Li H B, Hou J, Lei X Y, Chen X H, Yuan Z G, Guo Z Z, Wang J, Guo Y B, et al. Morphology and distribution of subsurface damage in optical fused silica parts: Bound-abrasive grinding. Appl Surf Sci 257(6): 20662073 (2011)
[2]
Zhao L J, Cheng J A, Chen M J, Yuan X D, Liao W, Liu Q, Yang H, Wang H J. Formation mechanism of a smooth, defect-free surface of fused silica optics using rapid CO2 laser polishing. Int J Extrem Manuf 1(3): 035001 (2019)
[3]
Cui Z J, Meng F W, Liang Y D, Zhang C, Wang Z X, Qu S, Yu T B, Zhao J. Sub-regional polishing and machining trajectory selection of complex surface based on K9 optical glass. J Mater Process Technol 304: 117563 (2022)
[4]
Zhang Z Y, Yan J W, Kuriyagawa T. Manufacturing technologies toward extreme precision. Int J Extrem Manuf 1(2): 022001 (2019)
[5]
Ge J Q, Ren Y L, Li C, Li Z, Yan S T, Tang P, Xu X S, Wang Q. Ultrasonic coupled abrasive jet polishing (UC-AJP) of glass-based micro-channel for micro-fluidic chip. Int J Mech Sci 244: 108055 (2023)
[6]
Beaucamp A T H, Freeman R R, Matsumoto A, Namba Y. Fluid jet and bonnet polishing of optical moulds for application from visible to x-ray. In Proc SPIE 8126, Optical Manufacturing and Testing IX, San Diego, California, USA, 2011: 240247
[7]
Feng J Y, Zhang Z Y, Yu S Q, Chen X, Wang D, Gu Q M, Zhou C C, Zhang T Y, Liu B X. Novel multiphase jet polishing for complicated structured components produced by laser powder bed fusion. Addit Manuf 72: 103634 (2023)
[8]
Zhao X C, Ma L R, Xu X F. Mode transition from adsorption removal to bombardment removal induced by nanoparticle-surface collisions in fluid jet polishing. Friction 9(5): 11271137 (2021)
[9]
Matsumura T, Muramatsu T, Fueki S. Abrasive water jet machining of glass with stagnation effect. CIRP Ann 60(1): 355358 (2011)
[10]
Qi H, Wen D H, Lu C D, Li G. Numerical and experimental study on ultrasonic vibration-assisted micro-channelling of glasses using an abrasive slurry jet. Int J Mech Sci 110: 94107 (2016)
[11]
Beaucamp A, Namba Y, Freeman R. Dynamic multiphase modeling and optimization of fluid jet polishing process. CIRP Ann 61(1): 315318 (2012)
[12]
Li Z Z, Li S Y, Dai Y F, Peng X Q. Optimization and application of influence function in abrasive jet polishing. Appl Opt 49(15): 29472953 (2010)
[13]
Cao Z C, Cheung C F. Theoretical modelling and analysis of the material removal characteristics in fluid jet polishing. Int J Mech Sci 89: 158166 (2014)
[14]
Cao Z C, Cheung C F, Ren M. Modelling and characterization of surface generation in fluid jet polishing. Precis Eng 43: 406417 (2016)
[15]
Wang C J, Cheung C F, Liu M Y. Numerical modeling and experimentation of three dimensional material removal characteristics in fluid jet polishing. Int J Mech Sci 133: 568577 (2017)
[16]
Oka Y I, Okamura K, Yoshida T. Practical estimation of erosion damage caused by solid particle impact. Wear 259(1–6): 95101 (2005)
[17]
Oka Y I, Yoshida T. Practical estimation of erosion damage caused by solid particle impact. Wear 259(1–6): 102109 (2005)
[18]
Mohammad Jafar R H, Spelt J K, Papini M. Numerical simulation of surface roughness and erosion rate of abrasive jet micro-machined channels. Wear 303(1–2): 302312 (2013)
[19]
Delnoij E, Lammers F A, Kuipers J A M, van Swaaij W P M. Dynamic simulation of dispersed gas-liquid two-phase flow using a discrete bubble model. Chem Eng Sci 52(9): 14291458 (1997)
[20]
Finnie I. Erosion of surfaces by solid particles. Wear 3(2): 87103 (1960)
[21]
Bitter J G A. A study of erosion phenomena part I. Wear 6(1): 521 (1963)
[22]
Majumdar A, Bhushan B. Fractal model of elastic-plastic contact between rough surfaces. J Tribol 113(1): 111 (1991)
[23]
Sayles R S, Thomas T R. Surface topography as a nonstationary random process. Nature 271(5644): 431434 (1978)
[24]
Majumdar A, Tien C L. Fractal characterization and simulation of rough surfaces. Wear 136(2): 313327 (1990)
[25]
Majumdar A, Bhushan B. Role of fractal geometry in roughness characterization and contact mechanics of surfaces. J Tribol 112(2): 205216 (1990)
[26]
Gagnepain J J, Roques-Carmes C. Fractal approach to two-dimensional and three-dimensional surface roughness. Wear 109(1–4): 119126 (1986)
[27]
Brown C A, Savary G. Describing ground surface texture using contact profilometry and fractal analysis. Wear 141(2): 211226 (1991)
[28]
Chen Z Y, Liu Y, Zhou P. A comparative study of fractal dimension calculation methods for rough surface profiles. Chaos Solitons Fractals 112: 2430 (2018)
[29]
Huang C K, Chiovelli S, Minev P, Luo J L, Nandakumar K. A comprehensive phenomenological model for erosion of materials in jet flow. Powder Technol 187(3): 273279 (2008)
[30]
Hutchings I M. A model for the erosion of metals by spherical particles at normal incidence. Wear 70(3): 269281 (1981)
[31]
Wang C J, Cheung C F, Ho L T, Liu M Y, Lee W B. A novel multi-jet polishing process and tool for high-efficiency polishing. Int J Mach Tools Manuf 115: 6073 (2017)
[32]
Goodwin J E, Sage W, Tilly G P. Study of erosion by solid particles. Proc Inst Mech Eng 184(1): 279292 (1969)
Friction
Pages 1548-1563
Cite this article:
CAO Z, WANG M, LIU H, et al. Modeling and analysis for material removal and surface roughness in fluid jet polishing of optical glass. Friction, 2024, 12(7): 1548-1563. https://doi.org/10.1007/s40544-023-0832-9

514

Views

64

Downloads

1

Crossref

1

Web of Science

1

Scopus

0

CSCD

Altmetrics

Received: 29 May 2023
Revised: 07 September 2023
Accepted: 20 September 2023
Published: 08 February 2024
© The author(s) 2023.

Open Access This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made.

The images or other third party material in this article are included in the article’s Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder.

To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/.

Return