王坤,李方祺,吕伊凡,朱伟光,张松泽.SLM增材制造弯管磨粒流抛光防过磨创新结构设计与试验研究[J].表面技术,2025,54(6):162-172.
WANG Kun,LI Fangqi,LYU Yifan,ZHU Weiguang,ZHANG Songze.Design and Experimental Study of Innovative Anti-wear Structure for SLM Additive Manufacturing Bend Pipe by Abrasive Flow Polishing[J].Surface Technology,2025,54(6):162-172 |
| SLM增材制造弯管磨粒流抛光防过磨创新结构设计与试验研究 |
| Design and Experimental Study of Innovative Anti-wear Structure for SLM Additive Manufacturing Bend Pipe by Abrasive Flow Polishing |
| 投稿时间：2024-07-17 修订日期：2024-12-30 |
| DOI：10.16490/j.cnki.issn.1001-3660.2025.06.015 |
| 中文关键词: 增材制造 磨粒流加工 弯管过磨 弯管结构设计 数值模拟 试验分析 |
| 英文关键词:additive manufacturing abrasive flow machining over-machining of bend pipes structural design of bend pipe numerical simulation experimental analysis |
| 基金项目:2021年内蒙古工业大学科研启动金项目(DC2200000931);2023年内蒙古自治区直属高校基本科研业务费项目(JY2023003) |
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| Author | Institution |
| WANG Kun | College of Mechanical Engineering, Inner Mongolia University of Technology, Hohhot 010010, China |
| LI Fangqi | College of Mechanical Engineering, Inner Mongolia University of Technology, Hohhot 010010, China |
| LYU Yifan | College of Mechanical Engineering, Inner Mongolia University of Technology, Hohhot 010010, China;Falcon Tech Co., Ltd., Jiangsu Wuxi 214000, China |
| ZHU Weiguang | College of Mechanical Engineering, Inner Mongolia University of Technology, Hohhot 010010, China |
| ZHANG Songze | College of Mechanical Engineering, Inner Mongolia University of Technology, Hohhot 010010, China |
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| 中文摘要: |
| 目的 针对磨粒流抛光直角弯处因磨料惯性力梯度变化导致肘部流道外侧过磨问题，提出一种带有创新保护结构的弯管设计方法。方法 以不均匀增厚、条状凸起和半球凸起结构弯管为实验对象，通过数值模拟和磨粒流实验相结合的方法，研究3种创新结构设计弯管内表面在磨粒流光整工艺加工下各样点压力与流道形状对弯管肘部材料去除量的影响。结果 仿真和实验结果揭示了各结构弯管的压力变化趋势，以及去除量的分布特征。在10 MPa的加工压力和100次的循环加工次数下，不均匀增厚弯管在入口倒角处存在压力增大突变，所以在倒角处、弯管段去除量最大，比普通弯管增加了20.7%。2种凸起结构在弯管段外侧压力随凸起结构的阻滞作用加剧而突变增大，随形磨削导致外侧凸起结构处去除量变化波动加剧，相比普通弯管分别增加了67.2%和47.5%，内侧去除量相比普通弯管也显著提升，分别提升172%和151%。结论 不均匀增厚弯管可以显著减少肘部过磨，保持内壁表面连续均匀的梯度变化，而凸起结构导致去除量波动，虽然可以减少过磨但难以控制稳定的表面粗糙度，所以不均匀增厚弯管结构对肘部流道外侧过磨问题具有较好的工程应用价值。 |
| 英文摘要: |
| As an advanced surface treatment technology, abrasive flow technology has demonstrated excellent results in 3D printing application. It can remove surface burrs and improve accuracy and surface quality, with environmental protection and energy saving advantages. However, during the processing of complex internal flow channel surfaces, uneven processing phenomena can occur. Therefore, the work aims to address the issue of excessive wear on the exterior of the elbow runner at right angles, which is caused by variations in the gradient of abrasive inertia force during abrasive flow polishing, and enhance the uniformity of processing in elbow components. To achieve this, three innovative structural designs for elbows were proposed by modifying the geometry of the flow channel. The effects of various point pressures and flow channel shapes on material removal and surface quality were studied through numerical simulation and experimental analysis. A 3D-printed aluminum alloy bend pipe was used as the test object. The process parameters were determined through tests, and the abrasive flow processing was simulated with the Carreau-Yasuda equation for non-Newtonian fluids. The simulation parameters of the outer pressure in the bend pipe were obtained and divided into two groups for comparison. The pipe bending was modeled with SolidWorks software, and the model was then imported into Fluent for simulation. The simulation results showed that the pressure of the non-uniform thickening type was larger than that of the ordinary type, and the pressure trend of the bar type and the half ball type was almost the same. During the machining test, the removal amount on the outer side of the bend was measured, and the sample points where the cutting amount changed were analyzed. Finally, the shape accuracy of the bend pipe was analyzed by 3D scanner. Under a processing pressure of 10 MPa and after 100 processing cycles, the removal amount for both ordinary and uneven thickened bend pipes initially increased and then decreased. The uneven thickened bend exhibited the greatest removal at the chamfer and the bend section, increasing by 20.7% compared to the ordinary bend. Due to the increased processing allowance of the uneven thickened protection structure, the overall surface consistency of the inner wall of the bend was better. The cutting amount for strip and hemispherical bend pipes increased sharply at the protruding structures, with increase of 67.2% and 47.5% respectively compared to ordinary bend pipes. The protruding part deformed after processing, which affected the practical use. The inner removal for strip and hemispherical bend pipes was significantly improved compared to ordinary bend pipes, increasing by 172% and 151% respectively. The process parameters of machining pressure and machining times are determined by experiments, and the surface quality after bending with three optimized structure designs is explored. It is found that the surface quality of the bend pipe with the uneven thickening design is superior, offering theoretical guidance for further optimization of bend pipe structures and abrasive flow machining experiments. |
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