增材制件内腔微细流道水基磨粒流光整加工流场仿真与试验验证
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南京航空航天大学机电学院, 南京 210016

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通讯作者:

孙玉利, 男, 教授, 博士生导师, E-mail: sunyuli@nuaa.edu.cn。

中图分类号:

TH161.1

基金项目:

南京航空航天大学博士拔尖人才跨学科创新基金(KXKCXJJ202404)。


Flow Field Simulation and Experimental Validation of Water-Based Abrasive Flow Machining for Internal Micro-channels in Additively Manufactured Components
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College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics & Astronautics, Nanjing 210016, China

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    摘要:

    针对增材制件内腔微细流道存在的表面质量差及抛光均匀性不佳问题,鉴于传统光整加工方法不适用且单向加工存在局限,本文采用双向光整加工模式,结合仿真与试验,系统研究了碳化硅与氧化铝两种水基磨料在单向和双向加工条件下对流道扩孔均匀性、表面粗糙度及表面形貌的影响。研究表明:相较单向加工,双向加工显著改善了流道抛光均匀性,使采用碳化硅磨料加工的流道入口与出口扩孔量差异从51 μm缩小至27 μm,采用氧化铝磨料加工的流道差异则从40 μm缩小至20 μm;同时,双向加工后各区域表面粗糙度明显降低且更均匀:碳化硅磨料加工的流道入口、出口及中间区域粗糙度分别降至3.726、3.612和3.639 μm,氧化铝磨料加工的流道相应区域则降至4.127、3.876和3.963 μm。对比两种磨料,碳化硅的抛光性能优于氧化铝,在双向加工模式下,其加工的流道表面粗糙度比氧化铝加工的流道平均低约0.3 μm(入口低0.4 μm,出口低0.26 μm,中间低0.32 μm)。

    Abstract:

    To address the poor surface quality and non-uniform polishing in internal micro-channels of additively manufactured components, where traditional finishing methods are inapplicable and unidirectional processing exhibits limitations, this study adopts a bidirectional finishing mode. Combining simulation and experimentation, it systematically investigates the effects of water-based silicon carbide (SiC) and alumina (Al?O?) abrasives on hole enlargement uniformity, surface roughness, and surface morphology under both unidirectional and bidirectional processing conditions. Results demonstrate that bidirectional processing significantly improves polishing uniformity compared with unidirectional processing. Specifically, the difference in hole enlargement between inlet and outlet is reduced from 51 μm to 27 μm using SiC abrasives, and from 40 μm to 20 μm using Al2O3 abrasives. Furthermore, bidirectional processing markedly reduces and homogenizes surface roughness across all regions: Roughness values in SiC-processed channels decrease to 3.726 (inlet), 3.612 (outlet), and 3.639 μm (middle), while those in Al?O?-processed channels decrease to 4.127 (inlet), 3.876 (outlet), and 3.963 μm (middle). Comparative analysis indicates SiC outperformes Al?O?, yielding channels with an average surface roughness approximately 0.3 μm lower under bidirectional processing (inlet: 0.4 μm lower, outlet: 0.26 μm lower, middle: 0.32 μm lower).

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曹文涛,孙玉利,闫哲,杨范轩,卢文壮,左敦稳.增材制件内腔微细流道水基磨粒流光整加工流场仿真与试验验证[J].南京航空航天大学学报,2026,58(1):46-57

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  • 收稿日期:2025-06-20
  • 最后修改日期:2025-09-17
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  • 在线发布日期: 2026-03-10
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