The enhanced performance of aerospace equipment drives parts development towards integration,complexity,and structural optimization.This advancement promotes metal near-net fabrication technologies like wire electrica...The enhanced performance of aerospace equipment drives parts development towards integration,complexity,and structural optimization.This advancement promotes metal near-net fabrication technologies like wire electrical discharge machining(WEDM)and 3D printing.However,the high initial surface roughness from WEDM or 3D printing poses significant challenges for the high-performance surface finishing required.To effectively reduce the surface roughness of the workpieces with high initial surface roughness,this paper proposes pulsed unipolar-polarisation plasma electrolytic polishing(PUP-PEP).The study examined the material removal mechanisms and surface polishing quality of PUP-PEP.This technique combines the high current density and material removal rate of the electrolytic polishing mode with the superior surface polishing quality of PEP through voltage waveform modulation.For an Inconel-718 superalloy part fabricated by WEDM,PUP-PEP reduced surface roughness from R_(a)7.39μm to R_(a)0.27μm in 6 min under optimal conditions.The roughness decreased from R_(a)7.39μm to R_(a)0.78μm in the first 3 min under pulsed unipolar-polarisation voltage,resulting in a remarkable 233%increase in efficiency compared to that with conventional PEP.Subsequently,the voltage output voltage is transformed into a constant voltage mode,and PEP is continued based on PUP-PEP to finally reduce the workpiece surface roughness value to R_(a)0.27μm.The proposed PUP-PEP technology marks the implementation of‘polishing’instead of conventional rough-finish machining processes,presenting a new approach to the surface post-processing of metal near-net fabrication technologies.展开更多
It is a challenge to polish the interior surface of an additively manufactured component with complex structures and groove sizes less than 1 mm.Traditional polishing methods are disabled to polish the component,meanw...It is a challenge to polish the interior surface of an additively manufactured component with complex structures and groove sizes less than 1 mm.Traditional polishing methods are disabled to polish the component,meanwhile keeping the structure intact.To overcome this challenge,small-grooved components made of aluminum alloy with sizes less than 1 mm were fabricated by a custom-made printer.A novel approach to multi-phase jet(MPJ)polishing is proposed,utilizing a self-developed polisher that incorporates solid,liquid,and gas phases.In contrast,abrasive air jet(AAJ)polishing is recommended,employing a customized polisher that combines solid and gas phases.After jet polishing,surface roughness(Sa)on the interior surface of grooves decreases from pristine 8.596μm to 0.701μm and 0.336μm via AAJ polishing and MPJ polishing,respectively,and Sa reduces 92%and 96%,correspondingly.Furthermore,a formula defining the relationship between linear energy density and unit defect volume has been developed.The optimized parameters in additive manufacturing are that linear energy density varies from 0.135 J mm^(-1)to 0.22 J mm^(-1).The unit area defect volume achieved via the optimized parameters decreases to 1/12 of that achieved via non-optimized ones.Computational fluid dynamics simulation results reveal that material is removed by shear stress,and the alumina abrasives experience multiple collisions with the defects on the heat pipe groove,resulting in uniform material removal.This is in good agreement with the experimental results.The novel proposed setups,approach,and findings provide new insights into manufacturing complex-structured components,polishing the small-grooved structure,and keeping it unbroken.展开更多
基金Supported by National Natural Science Foundation of China(Grant No.52205476)the Youth Talent Support Project of Jiangsu Provincial Association of Science and Technology(Grant No.TJ-2023-070)+1 种基金the Fund of Prospective Layout of Scientific Research for Nanjing University of Aeronautics and Astronautics(Grant No.1005-ILB23025-1A)the Fund of Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology(Grant No.1005-ZAA20003-14).
文摘The enhanced performance of aerospace equipment drives parts development towards integration,complexity,and structural optimization.This advancement promotes metal near-net fabrication technologies like wire electrical discharge machining(WEDM)and 3D printing.However,the high initial surface roughness from WEDM or 3D printing poses significant challenges for the high-performance surface finishing required.To effectively reduce the surface roughness of the workpieces with high initial surface roughness,this paper proposes pulsed unipolar-polarisation plasma electrolytic polishing(PUP-PEP).The study examined the material removal mechanisms and surface polishing quality of PUP-PEP.This technique combines the high current density and material removal rate of the electrolytic polishing mode with the superior surface polishing quality of PEP through voltage waveform modulation.For an Inconel-718 superalloy part fabricated by WEDM,PUP-PEP reduced surface roughness from R_(a)7.39μm to R_(a)0.27μm in 6 min under optimal conditions.The roughness decreased from R_(a)7.39μm to R_(a)0.78μm in the first 3 min under pulsed unipolar-polarisation voltage,resulting in a remarkable 233%increase in efficiency compared to that with conventional PEP.Subsequently,the voltage output voltage is transformed into a constant voltage mode,and PEP is continued based on PUP-PEP to finally reduce the workpiece surface roughness value to R_(a)0.27μm.The proposed PUP-PEP technology marks the implementation of‘polishing’instead of conventional rough-finish machining processes,presenting a new approach to the surface post-processing of metal near-net fabrication technologies.
基金the National Key Research and Development Program of China(2018YFA0703400)the Young Scientists Fund of the National Natural Science Foundation of China(52205447)Changjiang Scholars Program of the Chinese Ministry of Education。
文摘It is a challenge to polish the interior surface of an additively manufactured component with complex structures and groove sizes less than 1 mm.Traditional polishing methods are disabled to polish the component,meanwhile keeping the structure intact.To overcome this challenge,small-grooved components made of aluminum alloy with sizes less than 1 mm were fabricated by a custom-made printer.A novel approach to multi-phase jet(MPJ)polishing is proposed,utilizing a self-developed polisher that incorporates solid,liquid,and gas phases.In contrast,abrasive air jet(AAJ)polishing is recommended,employing a customized polisher that combines solid and gas phases.After jet polishing,surface roughness(Sa)on the interior surface of grooves decreases from pristine 8.596μm to 0.701μm and 0.336μm via AAJ polishing and MPJ polishing,respectively,and Sa reduces 92%and 96%,correspondingly.Furthermore,a formula defining the relationship between linear energy density and unit defect volume has been developed.The optimized parameters in additive manufacturing are that linear energy density varies from 0.135 J mm^(-1)to 0.22 J mm^(-1).The unit area defect volume achieved via the optimized parameters decreases to 1/12 of that achieved via non-optimized ones.Computational fluid dynamics simulation results reveal that material is removed by shear stress,and the alumina abrasives experience multiple collisions with the defects on the heat pipe groove,resulting in uniform material removal.This is in good agreement with the experimental results.The novel proposed setups,approach,and findings provide new insights into manufacturing complex-structured components,polishing the small-grooved structure,and keeping it unbroken.
