A novel approach of jet polishing for interior surface of small-grooved components using three developed setups
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 comp...
| Main Authors: | , , , , , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
IOP Publishing
2024-01-01
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| Series: | International Journal of Extreme Manufacturing |
| Subjects: | |
| Online Access: | https://doi.org/10.1088/2631-7990/ad1bba |
| _version_ | 1797352407078797312 |
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| author | Qinming Gu Zhenyu Zhang Hongxiu Zhou Jiaxin Yu Dong Wang Junyuan Feng Chunjing Shi Jianjun Yang Junfeng Qi |
| author_facet | Qinming Gu Zhenyu Zhang Hongxiu Zhou Jiaxin Yu Dong Wang Junyuan Feng Chunjing Shi Jianjun Yang Junfeng Qi |
| author_sort | Qinming Gu |
| collection | DOAJ |
| description | 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 8.596 μ m to 0.701 μ m and 0.336 μ m 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. |
| first_indexed | 2024-03-08T13:16:04Z |
| format | Article |
| id | doaj.art-25d2ab71c1634ee4b43c400efb4d111b |
| institution | Directory Open Access Journal |
| issn | 2631-7990 |
| language | English |
| last_indexed | 2024-03-08T13:16:04Z |
| publishDate | 2024-01-01 |
| publisher | IOP Publishing |
| record_format | Article |
| series | International Journal of Extreme Manufacturing |
| spelling | doaj.art-25d2ab71c1634ee4b43c400efb4d111b2024-01-18T06:42:33ZengIOP PublishingInternational Journal of Extreme Manufacturing2631-79902024-01-016202510110.1088/2631-7990/ad1bbaA novel approach of jet polishing for interior surface of small-grooved components using three developed setupsQinming Gu0Zhenyu Zhang1https://orcid.org/0000-0002-2393-520XHongxiu Zhou2Jiaxin Yu3Dong Wang4Junyuan Feng5Chunjing Shi6Jianjun Yang7Junfeng Qi8State Key Laboratory of High-performance Precision Manufacturing, Dalian University of Technology , Dalian 116024, People’s Republic of ChinaState Key Laboratory of High-performance Precision Manufacturing, Dalian University of Technology , Dalian 116024, People’s Republic of ChinaSchool of Energy and Power Engineering, Dalian University of Technology , Dalian 116024, People’s Republic of ChinaKey Laboratory of Testing Technology for Manufacturing Process, Ministry of Education, Southwest University of Science and Technology , Mianyang 621010, People’s Republic of ChinaState Key Laboratory of High-performance Precision Manufacturing, Dalian University of Technology , Dalian 116024, People’s Republic of China; Beijing Spacecraft Manufacturing Co., Ltd, China Academy of Space Technology , Beijing 100094, People’s Republic of ChinaState Key Laboratory of High-performance Precision Manufacturing, Dalian University of Technology , Dalian 116024, People’s Republic of ChinaSchool of Mechanical Engineering, Hangzhou Dianzi University , Hangzhou, Zhejiang, People’s Republic of ChinaFacility Design and Instrumentation Institute, China Aerodynamics Research and Development Center (CARDC) , Mianyang 621000, People’s Republic of ChinaBeijing Spacecraft Manufacturing Co., Ltd, China Academy of Space Technology , Beijing 100094, People’s Republic of ChinaIt 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 8.596 μ m to 0.701 μ m and 0.336 μ m 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.https://doi.org/10.1088/2631-7990/ad1bbaabrasive air jet polishingmulti-phase jet polishinginterior curved surfacesmall-grooved componentaluminum alloy |
| spellingShingle | Qinming Gu Zhenyu Zhang Hongxiu Zhou Jiaxin Yu Dong Wang Junyuan Feng Chunjing Shi Jianjun Yang Junfeng Qi A novel approach of jet polishing for interior surface of small-grooved components using three developed setups International Journal of Extreme Manufacturing abrasive air jet polishing multi-phase jet polishing interior curved surface small-grooved component aluminum alloy |
| title | A novel approach of jet polishing for interior surface of small-grooved components using three developed setups |
| title_full | A novel approach of jet polishing for interior surface of small-grooved components using three developed setups |
| title_fullStr | A novel approach of jet polishing for interior surface of small-grooved components using three developed setups |
| title_full_unstemmed | A novel approach of jet polishing for interior surface of small-grooved components using three developed setups |
| title_short | A novel approach of jet polishing for interior surface of small-grooved components using three developed setups |
| title_sort | novel approach of jet polishing for interior surface of small grooved components using three developed setups |
| topic | abrasive air jet polishing multi-phase jet polishing interior curved surface small-grooved component aluminum alloy |
| url | https://doi.org/10.1088/2631-7990/ad1bba |
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