中文摘要：

针对模具的细小尺度结构化表面难以进行光整加工的问题,提出一种基于固—液两相软性磨粒流精密加工新方法。利用软性磨粒流的湍流壁面效应,并配以约束模块,能够实现对模具结构化表面的无工具光整加工。基于对Preston方程及其修正系数的分析研究,确定了软性磨粒流加工中的颗粒选择条件,并得到适用于软性磨粒流的切削经验公式。采用可实现k-ε湍流模型以及SIMPLEC算法,对软性磨粒流的压力、速度分布及运动曲线进行数值分析;通过对不同规格颗粒对壁面的压力进行仿真研究,得到适用于软性磨粒流加工的最佳颗粒尺寸。基于上述理论分析与数值模拟结果,搭建软性磨粒流加工试验平台,进行不同入口条件下的加工对比试验,并详细分析入口条件对工件表面形貌的影响。试验结果表明,软性磨粒流加工方法可以实现细微尺寸结构化表面的光整加工,有效提高加工的精度。

英文摘要：

In allusion to the problem of tiny scale structural surface machining in mould manufacturing course,a new no-tools precision finishing method based on solid-liquid two phase softness abrasive flow（SAF） is brought forward.By setting restrained component for the machined surface,restrained flow passage is constructed.Using the wall effect of SAF,no-tools precision machining for tiny scale structural surface can be realized.By studying on Preston equation and Preston coefficients,selection criteria of particles for SAF machining are confirmed,and cutting empirical formula for SAF machining are obtained.Realizable k-ε model and SIMPLEC algorithm are used for numerical analyzing pressure and velocity distribution of SAF,and particles pressure on surface with different particle sizes are also simulated,the best particle size which is suit for SAF machining are derived by simulation results.Based on results of theoretical and simulation analysis,SAF experimental platform is constructed,machining experiments with different inlet conditions have been done,and impacts of inlet condition on workpiece surface shape are analyzed.Experiment results show that tiny scale structural surface machining can be realized,and machining method based on SAF can improve surface accuracy of tiny scale mould structural surface effectively.