液流边界主动约束的曲面高效超精密剪切增稠-化学协同抛光方法研究

To achieve ultra-precision polishing of curved surface with high efficiency, high quality and low cost, high efficiency and ultra-precision shear thickening-chemical synergistic polishing method (C-STP) for curved surface with active flow boundary constrained is proposed. The chemical-shear thickening polishing slurry (C-STPS) will be prepared, and the raw material is easy to obtain and the use-cost is low. Active flow boundary constrained using a polishing wheel with a certain texture surface can effectively control the flow field, pressure distribution and liquid film thickness, which will be conducive to the formation of “flexible fixed abrasive tool” with solid-like properties for C-STPS, improve surface profile goodness of fit, achieve deterministic material removal, promote the shear-thickening and chemical action with efficient synergism, and achieve the workpiece polishing with high-efficiency and high surface quality. The trajectory of polishing wheel will be adopted to improve the accuracy of surface profile, which can be used for curved surface high precision polishing. The chemical action of C-STPS will expand the range of processing materials, which can be used for the curved surface polishing of plastic and hard brittle materials. Based on theoretical analysis, numerical simulation and experimental study, mechanism and law of shear thickening-lubrication with active flow boundary constrained, the synergistic mechanism of shear thickening and chemical action and the mechanism of material removal, and the key technology of the application of this polishing method will be explored. The project will be expected to develop a shear thickening-chemical synergistic polishing method for curved surface with high efficiency and ultra-precision.

针对曲面的高效、高质量、低成本超精密抛光，提出液流边界主动约束的曲面高效超精密剪切增稠-化学协同抛光方法：制备具有剪切增稠-化学协同效应的抛光液（C-STPS），其原料易获取，使用成本低；利用有一定表面纹理的抛光轮主动约束液流边界，能有效地控制流场、压力分布及液膜厚度，利于C-STPS形成类固体特性的“柔性固着磨具”，提高面形吻合度，达到材料去除确定性，促使剪切增稠与化学作用高效率协同，实现工件高效、高质量的抛光；规划抛光轮轨迹，提高面形精度，能用于高精度曲面抛光；C-STPS的化学作用能拓展加工材料范围，可用于塑性、硬脆性材料的曲面抛光。通过理论分析、数值仿真和试验研究，揭示液流边界主动约束的剪切增稠-润滑流动机制及规律，揭示剪切增稠与化学作用协同机制及材料去除机理，探索该方法应用的关键技术，有望开发一种曲面高效超精密剪切增稠-化学协同抛光方法。

抛光一直是超精密加工最主要的一种方法，是降低工件表面粗糙度、去除损伤层，获得高精度和高表面质量的终加工手段。研究和开发高效高质量低成本超精密加工方法是抛光技术发展的主要方向之一。本项目针对曲面的高效高质量超精密抛光，提出并建立了一种液流边界主动约束的曲面高效超精密剪切增稠-化学协同抛光理论与技术方法：发明了一种新型剪切增稠-化学协同效应抛光液，自主设计开发了有望实现商业化的第一台剪切增稠-化学协同抛光智能装备；利用有一定表面纹理的抛光工具主动约束液流边界，能有效地控制流场、压力分布及液膜厚度，形成类固体特性的“柔性固着抛光工具”，大幅度提高了面形吻合度，达到材料去除确定性，并通过探索研究剪切增稠与化学效应高效率协同机制，建立了材料去除模型，实现了工件高效、高质量的可控抛光；规划柔性抛光工具的运行轨迹，有利于提高面形精度，实现了高精度曲面抛光；本项目所研发抛光方法可用于塑性、硬/软脆性材料（轴承钢、硬质合金、陶瓷材料、光学晶体材料等）的曲面抛光。通过理论分析、数值仿真和试验研究，揭示了液流边界主动约束的剪切增稠-润滑流动机制及规律，揭示了剪切增稠与化学效应协同机制及材料去除机理，探索出该方法应用的关键技术，成功开发一种曲面高效超精密剪切增稠-化学协同抛光新方法、新理论及新工艺，本项目技术成果有望在超精密制造与机床领域里得到进一步产业化应用。