Title: Numerical simulation and experimental research on abrasive flow machining of helical internal gear

Authors: Junye Li; Tiancheng Wang; Xinming Zhang; Liwei Sun; Lixiong Wang; Jianhe Liu; Weihong Zhao

Addresses: Ministry of Education Key Laboratory for Cross-Scale Micro and Nano Manufacturing, Changchun University of Science and Technology, Changchun 130022, China ' Ministry of Education Key Laboratory for Cross-Scale Micro and Nano Manufacturing, Changchun University of Science and Technology, Changchun 130022, China ' Ministry of Education Key Laboratory for Cross-Scale Micro and Nano Manufacturing, Changchun University of Science and Technology, Changchun 130022, China ' Ministry of Education Key Laboratory for Cross-Scale Micro and Nano Manufacturing, Changchun University of Science and Technology, Changchun 130022, China ' Ministry of Education Key Laboratory for Cross-Scale Micro and Nano Manufacturing, Changchun University of Science and Technology, Changchun 130022, China ' Ministry of Education Key Laboratory for Cross-Scale Micro and Nano Manufacturing, Changchun University of Science and Technology, Changchun 130022, China ' Ministry of Education Key Laboratory for Cross-Scale Micro and Nano Manufacturing, Changchun University of Science and Technology, Changchun 130022, China

Abstract: This study is a numerical simulation of the effects of inlet pressure and abrasive concentration factors on the machining of helical internal gears by the abrasive flow. The effects of static pressure, particle pressure and wall shear on the processing of helical internal gears by abrasive flow were analysed for different processing parameters. A surface roughness profiler and a scanning electron microscope are used to examine and analyse the gear tooth surface profile on a macroscopic and microscopic scale. The simulation and test results agree well with each other, verifying the validity and accuracy of the model, and obtaining the optimal combination of machining parameters and the order of significance of each factor affecting the machining effect. The surface roughness of the machined tooth face was reduced from 4.205 µm to 0.526 µm, effectively improving surface uniformity and surface quality, and providing an effective solution for precision machining of complex geometry parts.

Keywords: abrasive flow machining; helical internal gear; large eddy simulation; particle pressure; wall shear force; orthogonal experiment; surface quality.

DOI: 10.1504/IJAT.2024.140500

International Journal of Abrasive Technology, 2024 Vol.12 No.2, pp.167 - 188

Received: 12 Jul 2022
Accepted: 02 Jul 2023
Published online: 20 Aug 2024 *

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