Ruminant Molar-inspired Design and Performance Study of Textured Abrasive Lapping Tool
In the lapping process,as the lapping tool is in direct contact with the workpiece,the design of the morphological characteristics and the arrangement of textured patterns of the lapping tool have a decisive influence on the processing quality and efficiency.However,the textured pattern and morphological feature design in conventional lapping tools are usually simple and unitary,which makes them susceptible to problems such as uneven distribution of lapping force and abrasive particles,poor flowability of the lapping fluid,and inefficient utilization of abrasive particles resulting in low machining efficiency.This research combines bionic design to improve the lapping tool's morphological characteristics and pattern arrangement to enhance the lapping performance regarding materials removal rate and surface quality.Inspired by the chewing behavior of ruminants,a modular distributed surface lapping tool was designed by extracting the morphological features from the molar tooth surface.Then the finite element method was used to analyze the uniformity of the equivalent pressure distribution on the workpiece during the lapping.The regular arrangement lapping tool without featured morphological design and the modular arrangement lapping tool with bionic design were comparatively studied.Furthermore,the influence of the slurry fluid flow and the abrasive particles'retention behavior was analyzed using the Fluent software based on hydrodynamic simulation.Besides theoretical analysis and computer simulation,a set of verification experiments were also carried out.For a comparative experimental study of lapping aluminum alloy specimens,the light-cured 3D printing method was used to prepare a modular arrangement lapping tool with bionic design features and a regular arrangement lapping tool without any featured design.The quantitative effects of factors such as rotational speed,pressure,and morphological design features on the lapping performance of the tools were discussed by response surface analysis.The results of the comprehensive theoretical study and experimental data show that,compared with regular arrangement lapping tools without any featured design,the uniformity of pressure distribution on the contact surface of the workpiece under 4 N lapping force of modular arrangement lapping tool with bionic design features was improved.The grey level variance of the binarized image processing of the contact stress distribution was reduced to 3.78,indicating the improvement in uniformity of lapping force distribution.Moreover,when the flow rate of lapping fluid at the gap inlet of the morphological feature was taken as 2.400 m/s,the average flow rate at the gap outlet of the modular arrangement tool with bionic feature design was 0.211 m/s,which was 29.45%higher than that of other tools.With the same process conditions,the machined surface roughness Ra of the aluminum alloy specimens lapped with the molar-inspired bionic design tool was reduced from 0.301 μm to 0.188 μm,which was an improvement of 17.94%compared with that of the regular tools.An improvement of 34.47%was also achieved in the material removal rate when the lapping force was set at 5 N.In all,the design of the lapping tool's morphological features and pattern arrangement has an important influence on the force distribution,fluid flow,and effective abrasive retention during the machining process.Therefore,the proposed modular arrangement of the molar tooth bionic design tool can effectively improve material removal efficiency and surface finish quality compared with the regular lapping tools,which provides a new idea for the development of ultra-precision surface machining technology.
bionic designlapping toolsurface texture and topographylapping performanceslurry fluid flowabrasive retention
国家科技期刊平台
NSTL
万方数据
维普
