Abstract:  In response to the precision machining of frictionless aluminum alloy cylinder with anodized oxide films, a composite spiral abrasive flow polishing method was proposed. A simulation model was established to analyze the collision between particles and the wall in polishing processes, and the influences of particle velocity in different directions on polishing were investigated. The processing mechanism of the composite spiral abrasive flow polishing was revealed. The simulation results show that the composite spiral motion changes the trajectory of the abrasive particles, and the addition of rotational velocity enhances the effective stress of the abrasive. The effective plastic deformation of the wall increases with the spiral groove speed. Particle image velocimetry observation experimental results demonstrate that the composite spiral motion increases the rotational velocity of the abrasives and enhances the vorticity of the flow field. The experimental results show that the composite spiral abrasive flow polishing not only causes less damages to the aluminum alloy anodized film, and effectively improves the surface quality of the workpieces.

Key words: abrasive flow polishing, flow field simulation, particle motion, aluminum alloy cylinder

摘要： 针对无摩擦铝合金气缸表面阳极氧化膜的精密加工问题，提出复合螺旋磨粒流抛光方法。建立了抛光过程中颗粒与壁面碰撞的仿真模型，分析了磨粒各向速度对抛光的影响，揭示了复合螺旋磨粒流抛光的加工机理。仿真结果表明：复合螺旋运动改变了磨粒运动轨迹，磨粒叠加了旋转速度后，增大了磨粒的有效应力；壁面的有效塑性变形随螺旋槽转速的增大而增大。粒子图像测速观测实验结果表明，复合螺旋运动提高了磨粒旋转速度，增大了流场的涡旋量。加工实验结果表明，复合螺旋磨粒流抛光不仅对铝合金氧化膜破坏较少，且可以有效提高工件的表面质量。

关键词: 磨料流抛光, 流场仿真, 磨粒运动, 铝合金气缸