Study on the Electrorheological Ultra-Precision Polishing Process with an Annular Integrated Electrode

Area of Science:

• Materials Science
• Mechanical Engineering
• Manufacturing Processes

Background:

• Electrorheological (ER) polishing is an emerging ultra-precision finishing technique.
• It minimizes workpiece surface damage and is ideal for intricate, small-scale curved surfaces.

Purpose of the Study:

• To develop an ER polishing tool with an annular integrated electrode.
• To investigate the influence of six key factors on ER polishing performance.
• To analyze the effect of individual process parameters on surface roughness.

Main Methods:

• Development of an ER polishing tool featuring an annular integrated electrode.
• Execution of orthogonal experiments to evaluate six influencing factors: applied voltage, abrasive particle size, abrasive concentration, polishing gap, polishing time, and tool spindle speed.
• Experimental analysis of single process parameter effects on surface roughness.

Main Results:

• Determination of the influence order of the six investigated factors on ER polishing.
• Experimental data quantifying the impact of individual parameters on surface roughness.

Conclusions:

• The study establishes a hierarchy of factors affecting ER polishing efficiency and surface quality.
• Findings provide a foundation for optimizing ER polishing processes for ultra-precision finishing applications.