微孔的磨料水射流抛光CFD模拟及试验

崔子含; 韩冰; 吴鹏程; 李擎; 马小刚; 丁云龙

doi:10.13394/j.cnki.jgszz.2023.0120

微孔的磨料水射流抛光CFD模拟及试验

doi: 10.13394/j.cnki.jgszz.2023.0120

崔子含^{1, 2},
韩冰^1, ,,
吴鹏程¹,
李擎^{1, 3},
马小刚¹,
丁云龙¹

1.
辽宁科技大学机械工程与自动化学院, 辽宁鞍山 114051
2.
通用技术集团机床工程研究院有限公司大连分公司，辽宁大连 116620
3.
中国航发哈尔滨东安发动机有限公司, 哈尔滨 150066

基金项目: 辽宁省省科技厅重点研发计划（2023JH2/101300226）; 辽宁科技大学省级重点实验室开放课题基金（2023KFKT-07，2022100305）。

详细信息

通讯作者:
韩冰，1975年生，博士、教授。主要研究方向：精密加工。E-mail：hanb75@126.com

中图分类号: TG58; TG73; TG664
计量
- 文章访问数: 231
- HTML全文浏览量: 98
- PDF下载量: 11
- 被引次数: 0
出版历程
- 收稿日期: 2023-05-29
- 修回日期: 2023-08-24
- 录用日期: 2023-11-22
- 网络出版日期: 2024-09-25
- 刊出日期: 2024-08-20

CFD simulation and experiments of abrasive water jet polishing for micropores

CUI Zihan^{1, 2},
HAN Bing^{1
, ,},
WU Pengcheng¹,
LI Qing^{1, 3},
MA Xiaogang¹,
DING Yunlong¹

1.
School of Mechanical Engineering & Automation, University of Science and Technology Liaoning, Anshan 114051, Liaoning, China
2.
Dalian Company, Genertec Machine Tool Engineering Research Institute Co., Ltd., Dalian 116620, Liaoning, China
3.
Aero Engine Corporation of China Dong'an Engine Company Limited, Harbin 150066, China

摘要

摘要: 为解决飞秒激光微孔难以抛光的问题，结合磨料水射流去除函数稳定、自适应性强等特点，采用磨料水射流抛光方法提高飞秒激光微孔质量。利用Fluent软件对不同工艺参数下的磨料水射流微孔抛光过程进行计算流体力学（computational fluid dynamics，CFD）模拟，分析不同参数下的流场分布、侵蚀速率及壁面剪切力作用规律；然后通过响应面法对射流靶距、射流压力及磨料粒径等3因素进行优化试验，以微孔内壁面剪切力均方差为响应值，建立其响应面方程，获得最佳抛光参数组合并进行试验验证。结果表明：射流压力对微孔内壁面剪切力的影响最大，当射流压力从0.80 MPa增至1.50 MPa时，微孔内壁面剪切力增大2倍以上。射流的不同结构段因性质不同可适用于不同工况。利用响应面法分析得到水射流微孔抛光的最佳工艺参数组合是：射流冲击角，90°；射流靶距，3.5 mm；射流压力，1.10 MPa；磨料粒径，15.0 μm。在该条件下抛光微孔内壁面的表面粗糙度R_a降至0.354 µm。磨料水射流抛光可显著改善微孔壁面质量，且响应面法预测的数据模型有较高准确性。
- 磨料水射流 /
- 飞秒激光微孔 /
- 计算流体力学 /
- 壁面剪切力 /
- 响应面法
Abstract: Objectives: Femtosecond laser technology has become the primary method for micropore processing due to its high precision and low energy consumption. However, during the process, it is easy to cause microcracks and burrs in the micropores. Additionally, due to the small size, low structural stability and weak wear resistance of the micropores, conventional methods are ineffective in polishing them. To address the challenge of polishing femtosecond laser-processed micropores, the abrasive water jet polishing method is employed. This method leverages the stable removal function and strong adaptability of the abrasive water jet to improve the quality of femtosecond laser-processed micropores. Methods: Computational fluid dynamics (CFD) simulations of the abrasive water jet micropore polishing process under different process parameters were carried out by using Fluent software. A finite element model of abrasive water jet polishing for femtosecond laser-processed micropores was established under various working conditions. The flow field distribution, the erosion rate and the wall shear force under different parameters were analyzed. Corresponding experiments were conducted for each variable discussed in the Fluent simulation, and the variation patterns of micropore inner wall roughness were summarized. Subsequently, optimization experiments were conducted on the three factors, namely jet target distance, jet pressure and abrasive particle size, using the response surface method. The mean square error of shear force on the inner wall of the hole was taken as the response value Y, and the response surface equation was established. The optimal polishing parameter combination was obtained through the response surface equation and experimentally verified. Results: A jet impact angle of 90° is suitable for polishing the inner wall of the micropore, as wall erosion is uniform and the shear force distribution is concentrated at this angle. At a target distance of 4.2 to 6.0 mm, the jet on the end face enters the deceleration stage, and the jet velocity decreases as the target distance increases. The shear force increases with increasing jet pressure. When the jet pressure is 0.80 MPa, the shear force is the smallest, concentrated in the range of 1 500 to 3 500 Pa. At a jet pressure of 1.50 MPa, the shear force is the largest, concentrated in the range of 3 500 to 5 500 Pa. When jet pressure increases from 0.80 to 1.50 MPa, the shear force on the inner wall of the hole increases more than twice. The effects of abrasive particle size and jet pressure on wall shear force are similar. When the abrasive particle size is 1.0 μm, the shear force is the smallest, concentrated in the range of 1 000 to 2 500 Pa. At an abrasive particle size of 30.0 μm, the shear force reaches its maximum, concentrated between 3 000 and 5 500 Pa. Corresponding tests are carried out for each variable discussed in the simulation, and the minimum roughness R_a of the inner wall of the micropore was 0.386 μm. The optimal process parameter combination obtained through response surface analysis is as follows: jet impact angle of 90°, jet target distance of 3.5 mm, jet pressure of 1.10 MPa, and abrasive particle size of 15.0 μm. Under the optimal parameter combination, with an abrasive mass fraction of 5% and a polishing time of 5.0 minutes, the surface roughness R_a of the polished micropore inner wall surface was reduced to 0.354 µm, which is better than the minimum roughness of 0.386 µm observed in the simulation. Polishing efficiency is improved by about 3%, and the quality of the micropore inner wall surface is further enhanced. Conclusions: When the impact angle is constant, the shear force on the inner wall of the hole increases with increasing jet pressure and abrasive particle size. It increases first and then decreases with the increase in jet target distance, with jet pressure having the greatest influence on the wall shear force. Different structural segments of the jet can be applied to different working conditions due to different properties. Additionally, the simulation and experimental results are in good agreement, and the improvement in roughness is significant. This indicates that abrasive water jet polishing significantly enhances the quality of micropore walls, and the data model for response surface prediction has high accuracy.
- abrasive water jet /
- femtosecond laser micropore /
- computational fluid dynamics(CFD) /
- wall shear force /
- response surface method (RSM)

HTML全文

图 1 磨料水射流抛光微孔系统

Figure 1. Abrasive water jet polishing micropore system

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图 2 飞秒激光微孔结构

Figure 2. Femotosecond laser micropore structure

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图 3 喷嘴的物理模型及网格模型

Figure 3. Physical model and grid model of nozzle

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图 4 微孔冲蚀云图

Figure 4. Micropore erosion nephogram

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图 5 不同冲击角下的壁面剪切力散点图

Figure 5. Scatter diagram of wall shear force for different impact angles

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图 6 不同射流靶距下的射流速度仿真云图

Figure 6. Simulation cloud map of jet velocity at different jet target distance

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图 7 不同射流靶距下的内壁面剪切力散点图

Figure 7. Scatter plot of inner wall shear forces at different target distances

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图 8 不同射流压力下的内壁面剪切力散点图

Figure 8. Scatter plot of inner wall shear forces at different jie pressures

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图 9 不同磨料粒径下的内壁面剪切力散点图

Figure 9. Scatter plot of inner wall shear forces at different abrasive sizes

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图 10 加工后的孔内壁面粗糙度值

Figure 10. Roughness value of inner wall surface of the hole after machining

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图 11 响应曲面图

Figure 11. RSM diagram

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图 12 微孔的微观形貌

Figure 12. Micro morphology of micropores

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表 1 试验设计的因子及水平

Table 1. Factors and levels of experimental design

水平因素
射流靶距
d₂ / mm
A 射流压力
F₂ / MPa
B 磨料粒径
d₃ / μm
C

−1 1.2 0.80 1.0
0 3.6 1.15 15.5
1 6.0 1.50 30.0

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